Note: Descriptions are shown in the official language in which they were submitted.
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ADJUSTABLE HELMET ASSEMBLY
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent
Appl. Serial No.
62/657,744 entitled "Collapsible Helmet Impact Zones," filed April 14, 2018,
U.S. Provisional Patent
Appl. Serial No. 62/716,066 entitled "No Tool Adjustable Helmet System," filed
August 08, 2018 and
U.S. Provisional Patent Appl. Serial No. 62/792,573 entitled "No Tool
Adjustable Helmet System, filed
January 15, 2019, which all the disclosures are incorporated by reference
herein in its entireties.
TECHNICAL FIELD
[0002] The present invention relates to an adjustable helmet system
assembly and a method for
fitting the adjustable helmet system assembly to a wearer's head. The
adjustable helmet system assembly
includes a locking mechanism that allows the front shell to be movable or
slidable to a rear shell to adjust
to a desired length. Furthermore, the adjustable helmet system assembly may
incorporate crumple zones
or crumple features that allow the adjustable helmet system assembly to
undergo structural changes in a
pre-determined fashion so that the structural changes are recoverable but yet
provide protection.
BACKGROUND OF THE INVENTION
[0003] Adjustable helmets have been known in the art for years, and used
in different
applications such as sports, firefighting, construction work, and the
military. In particular, many of these
adjustable helmets allow the wearer to adjust the helmet size to fit a
particular head. For example, helmet
adjustment mechanisms have consisted of a stud and notch or a headband with a
rack and pinion adjusting
mechanism, and/or by loosening and tightening screws.
[0004] Although, these and other conventional adjustment mechanisms have
worked well, they
have failed in a number of areas. For instance, loosening and tightening
screws increase the length of
adjustment time, require that the user carries tools and do not allow the
helmet wearer to adjust the size of
the helmet while wearing the helmet and/or adjust the helmet quickly.
Accordingly, the helmet wearer
must remove the helmet, adjust the helmet, and retry the helmet size multiple
times before a proper fit can
be established.
[0005] Also, in many other adjustable helmet designs, the adjustment does
not allow the comfort
liner padding to be properly fitted to the head of the user. Comfort liner
padding assemblies are usually
provided in standard sizes (e.g., small to xlarge) and are affixed to the
helmet. The comfort liner padding
assemblies are not adjustable, these variances create significant difficulties
in having the helmet sized
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correctly with the comfort liner pad system. The comfort liner pad system may
be improperly positioned,
too large or too small preventing or decreasing the safety of its intended
function.
[0006] Furthermore, the previous adjustable helmet designs are usually
manufactured from rigid
or substantially rigid polymers. These rigid polymers do not perform as
intended because they lack the
ability absorb a significant amount of energy after an impact and/or
manufacturers tend to increase the
relative thickness of the material. Using such materials or increased
thicknesses, allows the impact force
to be transferred to the wearer's head, thus causing severe traumatic brain
injuries or result in adding
unnecessary weight/imbalance resulting in disproportionate measurements for
optimal muscle control.
Accordingly, the impact force can also be transferred to other portions of the
helmet, potentially causing
premature disengagement of the helmet shells and exposing the wearer to
further traumatic brain injuries.
BRIEF SUMMARY OF THE INVENTION
[0007] It is therefore an object of the present invention to provide an
adjustable helmet system
with improved locking mechanisms and crumple zones that can overcome some of
the disadvantages of
the previous helmet designs. The adjustable helmet system offers a two-piece
helmet that allows
adjustment of the helmet quickly and efficiently without the need for tools,
allow the impact mitigation
layers and/or comfort liners pad systems to be easily disconnected and/or
adjusted within the helmet,
and/or provide for controlled localized deflection and/or deformation through
the incorporation of
structural features that promote the absorption of energy from an impact
resulting in reduced forces
experienced by the wearer and other portions of the helmet.
[0008] Another practical advantage with this adjustable helmet system
that also improves safety
by enabling a better customizing to fit different head shapes such as oval,
oblong and round, not just adapt
to sizes. Parents will be able to customize the helmets as their children
grow, thus avoiding the
understandable but dangerous habit of buying large so that the child will
'grow into it'. A frontal fall in a
helmet that is too large, forces the helmet backwards and can force the back
of the helmet into the neck at
the base of the skull, at the anatomical area of the brain stem, with tragic
results often worse than if a
helmet had not been worn at all.
[0009] In one embodiment, the adjustable helmet system may comprise a
locking system. The
adjustable helmet system comprises a first (or front) shell; a second (or
back) shell, the second shell being
slidably attached to the first shell; a locking mechanism, the locking
mechanism being movable between a
first unlocked position which allows the first and second shells to slide
relative to each other and a second
locked position which inhibits the first and second shells from sliding
relative to each other.
[00010] In one embodiment, an adjustable helmet system may comprise a
helmet clamp locking
mechanism assembly. The adjustable helmet system may comprise a front shell, a
back shell, and a
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clamp locking assembly. The clamp locking assembly will facilitate easy no-
tool detachment and
securement by using a lever function. To adjust a representative helmet, the
user may lift the clamp body
allowing the clamp post to place a downward compressive force against the
clamp tongue thereby
releasing the front and back shells to move relative to each other.
Conversely, to secure or lock the clamp
locking assembly, the user will push the clamp body down within the cavity
allowing the base plate
coupled to the clamp post to place an upward compressive force to sandwich the
front and back shells and
prevent movement and have the plurality of teeth engage with the plurality of
recesses. Alternatively, the
helmet may further comprise helmet alignment guides. The helmet alignment
guides may be strategically
placed onto the helmet and can be placed within any region of the helmet,
including frontal, ridge (or
top), and/or the sides (right or left). The helmet alignment guides will help
align the front and back shells
in the proper position during adjustment.
[00011] In one embodiment, the adjustable helmet system may comprise a
clamp locking
mechanism assembly that may be modular and coupled to any commercially
available helmet (retrofitting
a commercially available helmet). The clamp locking mechanism assembly may
comprise at least one of
a clamp housing, a clamp body, clamp post, a base plate, a clamp tongue and/or
any combination thereof
The clamp housing has a top surface and a bottom surface, at least a portion
of the top surface having a
cavity extending from the top surface towards the bottom surface, the cavity
sized and configured to
receive the clamp body, the cavity having an aperture, the aperture extends
through the top surface to the
bottom surface, the aperture is sized and configured to receive a clamp post,
the clamp post is pivotally
coupled to the clamp body; the clamp housing bottom surface having a plurality
of teeth, the plurality of
teeth extending outwardly from the bottom surface, the plurality of teeth
sized and configured to fit within
a plurality of recesses on a clamp tongue. The clamp tongue having a first
surface and a second surface,
at least a portion of the first surface including the plurality recesses, the
plurality of recesses sized and
configured to receive the clamp housing plurality of teeth, the clamp tongue
having a channel, the channel
extends through the first surface to the second surface, the channel sized and
configured to receive the
clamp post; the clamp post coupled to a base plate.
[00012] In another embodiment, the adjustable helmet system may comprise a
clamp locking
mechanism that may be integrated within a helmet. The adjustable helmet system
comprises a helmet and
a clamp locking mechanism assembly. The clamp locking mechanism assembly may
comprise at least
one of a clamp housing, a clamp body, clamp post, a base plate, a clamp
tongue, a spring and/or any
combination thereof The helmet having a front shell, and a back shell, at
least a portion of the front or
back shell having one or more alignment guides; the front or back shell may
have a clamp tongue, the
clamp tongue having a longitudinal length that extends outward from the front
or back shell, the clamp
tongue having a first surface and a second surface, at least a portion of the
first surface including a
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plurality recesses, the plurality of recesses sized and configured to receive
a plurality of teeth, the clamp
tongue having a channel, the channel extends through the first surface to the
second surface, the channel
sized and configured to receive the clamp post; the clamp post coupled to the
base plate; at least a portion
of the back or front shell having first surface and a second surface, the
front or back shell first surface
having a shell recess, the shell recess being sized and configured to fit a
clamp housing, the shell recess
having an shell aperture extends there through, the shell aperture being sized
and configured to receive
the clamp post; at least a portion of the front or back shell second surface
having a plurality of teeth, the
plurality of teeth sized and configured to fit within the plurality of
recesses. The clamp housing has a top
surface and a bottom surface, at least a portion of the top surface having a
cavity extending from the top
surface towards the bottom surface, the cavity sized and configured to receive
the clamp body, the cavity
having an aperture, the aperture extends through the top surface to the bottom
surface, the aperture is
sized and configured to receive a clamp post, the clamp post is pivotally
coupled to the clamp body.
[00013] In another embodiment, the adjustable helmet system may comprise
an alternate
embodiment of a clamp locking mechanism that may be integrated within a
helmet. The adjustable
helmet system may comprise a front shell (or first shell), and back shell (or
second shell), and a locking
mechanism. The locking mechanism including a clamp assembly, a plurality of
teeth, at least a portion of
the plurality of teeth sized and configured to fit within a portion of a
plurality of recesses, the plurality of
teeth disposed on the first or second shell, a plurality recesses, at least a
portion of the plurality of
recesses are sized and configured to receive the plurality of teeth, the
plurality of recesses disposed on the
first or second shell, the clamp assembly being movable between a unlocked
position that allows the
plurality of teeth and the plurality of recesses to disengage and allow the
first and second shells to slide
relative to each other, and a locked position that allows a portion of the
plurality of teeth and a portion of
the plurality of recesses to engage that inhibits the first and second shells
from sliding relative to each
other.
[00014] In another embodiment, the adjustable helmet system may comprise
crumple zones. The
adjustable helmet system may comprise a first shell, a second shell, the
second shell being slidably
attached to the first shell, a locking mechanism, and/or at least one opening.
The locking mechanism
being movable between an unlocked position which allows the first and second
shells to slide relative to
each other and a locked position which prohibits the first and second shells
from sliding relative to each
other. The at least one opening placed adjacent to, in proximity to or within
impact zones of the first or
second shells resulting in local deformation and reducing the translation of
impact forces from a portion
of the first shell and/or second shells. The impact zones are zones of a
wearer's head that may see higher
than normal frequency of impacts and/or magnitude of impacts. The impact zones
are within the occipital
region, temporal region, parietal region, orbit region, the frontal region,
the mandible (front, right and/or
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left side) region, the maxilla region, the nasal region, zygomatic region, the
ethmoid region, the lacrimal
region, the sphenoid region and/or any combination thereof
[00015] In another embodiment, the adjustable helmet system may further
comprise at least one
impact mitigation layer. The adjustable helmet system may comprise a front
shell (or first shell), a back
shell (or second shell), a locking mechanism, and at least one impact
mitigation layer. The at least one
impact mitigation layer may include one or more impact structures. The impact
structures may comprise
at least a portion of liner pod assemblies, at least a portion of filaments,
at least a portion of laterally
supported filaments (LSFs), at least a portion of auxetic structures, TPU (not
shown), inflatable bladders
(not shown), shock bonnets (not shown), at least one foam layer (not shown),
at least a portion of air
bladders, and/or any combination thereof The front shell and/or back shell may
have an external surface
and an internal surface, the at least one impact mitigation layer may be
coupled to the internal surface of
the front and/or back shells. Coupling may be fixed or removably coupled.
[00016] In another embodiment, the adjustable helmet system may further
comprise at least one
supplemental layer. The adjustable helmet system may comprise a front shell
(or first shell), a back shell
(or second shell), a locking mechanism, at least one impact mitigation layer
and at least one supplemental
layer. The front shell and/or back shells may have an external surface and an
internal surface, the
supplemental layer may be positioned proximate to the impact mitigation layer
and/or may be positioned
proximate to the internal surface of the front and/or back shells. The
supplemental layer may include a
plurality of liner pod assemblies or comfort liners that are desirably
positioned around various locations
of the wearer's head, covering much of the area inner surface of the helmet.
The liner pod assemblies
may include a pod and a connection mechanism. Such plurality of liner pod
assemblies may be
positioned within and/or proximate to one or more of the following regions: a
frontal assembly (or front),
an occipital assembly (or lower-back), a mid-back assembly, a parietal
assembly (or midline), and a
temporal assembly (right and/or left sides), and/or any combination(s) thereof
At least a portion of the
liner pod assemblies may be removably coupled to the helmet and/or any
combination thereof to increase
energy absorption, mitigation of linear or angular impact forces, enhance fit
and comfort.
[00017] In another embodiment, the adjustable helmet system may comprise a
cam locking
mechanism assembly. The cam locking assembly will facilitate easy no-tool
detachment and securement
by using a rotational function. To adjust a representative helmet, the user
may rotate the cam body
counter-clock position to allowing the cam post to place a downward
compressive force against the clamp
tongue thereby releasing the front and back shells to move relative to each
other. Conversely, to secure or
lock the cam locking assembly, the user will rotate the cam body to a clock-
wise position to lift the base
plate that coupled to the clamp post and place an upward compressive force to
sandwich the front and
back shells and prevent movement and have the plurality of teeth engage with
the plurality of recesses.
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Alternatively, the helmet may further comprise helmet alignment guides. The
helmet alignment guides
may be strategically placed onto the helmet and can be placed within any
region of the helmet, including
frontal, ridge (or top), and/or the sides (right or left). The helmet
alignment guides will help align the
front and back shells in the proper position during adjustment.
[00018] In one exemplary embodiment, at least one commercially available
(CA) may be
retrofitted to have one or more crumple zones. The at least one CA helmet may
comprise one or more
protrusions that may be modified or replaced with impact mitigation structures
or impact mitigation
features to create a crumple zone. The one or more protrusion may be modified
with impact mitigation
features that allow the collapsibility, compressibility and/or impact
absorption, the impact mitigation
features comprising a plurality of perforations, the plurality of perforations
may include a variety of
different shapes and/or configurations to enhance collapsibility,
compressibility and/or impact absorption.
Such shapes and/or configurations may include relief cuts, slits, holes,
openings, herringbone shape, zig-
zag shapes, chevron shapes, auxetic shapes, reentrant shapes, and/or any
combination thereof In another
exemplary embodiment, the one or more protrusion may incorporate at least one
impact mitigation
structure over the shell protrusions. Additionally, the one or more shell
protrusions may be replaced with
at least one impact mitigation structure. The at least one CA helmet shell
protrusions may have at least
one impact mitigation structure disposed within a cavity of the one or more
protrusions. Alternatively,
the at least one impact mitigation structure can be positioned between the at
least two protrusions.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[00019] FIGS. 1A-1F depicts various views of one embodiment of an
adjustable helmet assembly;
[00020] FIG. 1G depicts an exploded view of one embodiment of an
adjustable helmet assembly
of FIGS. 1A-1F;
[00021] FIGS. 2A-2J depict various various views of an alternate
embodiment of an adjustable
helmet assembly;
[00022] FIGS. 3A-3F depict various views of one embodiment of an
adjustable helmet first or
front shell;
[00023] FIGS. 4A-4F depict various views of one embodiment of an
adjustable helmet second or
back shell;
[00024] FIGS. 5A-5G depict various views of an alternate embodiment of an
adjustable helmet;
[00025] FIGS. 6A-6H depict various views of an alternate embodiment of a
clamp locking
mechanism assembly;
[00026] FIGS. 6I-6J depict an exploded isometric and side view of one
embodiment of a clamp
locking mechanism assembly of FIGS. 6A-6H;
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[00027] FIGS. 7A-7H depict various views of one embodiment of the clamp
housing;
[00028] FIGS. 8A-8H depict various views of one embodiment of a clamp
body;
[00029] FIGS. 9A-9H depict various views of one embodiment of a clamp
post;
[00030] FIGS. 10A-10H depict various views of one embodiment of a clamp
tongue;
[00031] FIGS. 11A-11H depict various views of one embodiment of a cam
locking mechanism
assembly;
[00032] FIGS. 11I-11J depict various exploded views of the cam locking
mechanism assembly of
FIGS. 11A-11H;
[00033] FIGS. 12A-12H depict various views of one embodiment of a cam
tongue;
[00034] FIGS. 13A-13H depict various views of one embodiment of the cam
housing;
[00035] FIGS. 14A-14H depict various views of one embodiment of a cam
post;
[00036] FIGS. 15A-15H depict various views of one embodiment of a cam
body;
[00037] FIGS. 16A-16F depict various views of an alternate embodiment of a
clamp body;
[00038] FIGS. 17A-17D depict various views and magnified views of a method
to open and close
a clamp locking assembly;
[00039] FIGS. 18A-18D depict various magnified views of a method to open
and close a clamp
locking assembly with engagement features;
[00040] FIGS. 19A-19E depict various views of one embodiment of an ear
protection;
[00041] FIGS. 20A-20I depict various views of different embodiments of
crumple zones on an
adjustable helmet;
[00042] FIGS. 21A-21F depict various views of different embodiments of
commercially available
helmets without crumple zones and locations of the at least one shell
protrusions;
[00043] FIGS. 22A-22B illustrate an alternate embodiment of a commercially
available (CA)
helmet without crumple zones;
[00044] FIG. 23 depict one embodiment of a CA helmet with at least one
impact mitigation
feature;
[00045] FIGS. 24A-24F depict various embodiments of impact mitigation
features shape and
configurations;
[00046] FIG. 25 depicts one embodiment of a CA helmet having impact
mitigation structure over
a shell protrusion;
[00047] FIGS. 26A-26B depicts one embodiment of a CA helmet having an
impact mitigation
structure replacing the shell protrusion;
[00048] FIG. 27 depicts one embodiment of a CA helmet having an impact
mitigation structure
disposed within the shell protrusion;
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[00049] FIGS. 28A-28D depict one embodiment of an impact mitigation
structure comprising
filaments;
[00050] FIGS. 29A-29C depict one embodiment of an impact mitigation
structure comprising
laterally supported filaments;
[00051] FIGS. 30A-30C depict one embodiment of an impact mitigation
structure comprising an
array of laterally supported filaments on a flexible layer;
[00052] FIGS. 31A-31B depict one embodiment of an impact mitigation
structure comprising
auxetic structures;
[00053] FIG. 32A-32C depict various embodiments of at least one impact
mitigation pads;
[00054] FIGS. 33A-33D depict various views of one embodiment of one or
more liner pod
assemblies;
[00055] FIGS. 34A-34B depict various bottom isometric views of an
alternate embodiment of one
or more liner pod assemblies;
[00056] FIGS. 35A-35D depict various views of one embodiment of a liner
pod assembly;
[00057] FIGS. 36A-36C depict various views of one embodiment of a
connection mechanism for
a liner pod assembly.
[00058] FIGS. 38A-38G depict various view of an alternate embodiment of an
adjustable helmet;
[00059] FIGS. 38H-38I depict a cross-sectional view and an exploded cross-
sectional view of the
alternate embodiment of the adjustable helmet of FIGS. 38A-38G;
[00060] FIGS. 39A-39H depict various views of an alternate embodiment of
an adjustable helmet
first or front shell;
[00061] FIGS. 40A-40G depict various views of an alternate embodiment of
an adjustable helmet
second or back shell;
[00062] FIGS. 41A-41G depict various views of an alternate embodiment of a
clamp body;
[00063] FIGS. 42A-42H depict various views of an alternate embodiment of a
clamp post;
[00064] FIGS. 43A-43F depict various views of an alternate embodiment of
an ear protection;
[00065] FIGS. 44A-44F depict various views of one embodiment of an ear
loop.
[00066] FIGS. 45 depicts a cross-sectional front view of the helmet and
impact mitigation layer;
[00067] FIGS. 46A-46B depict a side and cross-sectional view of one
embodiment of a
supplemental layer; and
[00068] FIGS. 47A-47C depict various views of one embodiment of a ridge or
crown foam pad.
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DETAILED DESCRIPTION OF THE INVENTION
[00069] The various improved locking mechanisms provided herein are
depicted with respect to
hockey, but it should be understood that the various devices and systems may
be suitable for use in
protecting players in various other athletic sports, as well as law
enforcement, military and/or informal
training session uses. For example, the embodiments of the present invention
may be suitable for use by
individuals engaged in athletic activities such as baseball, bowling, boxing,
cricket, cycling,
motorcycling, golf, hockey, lacrosse, soccer, rowing, rugby, miming, skating,
skateboarding, skiing,
snowboarding, surfing, swimming, table tennis, tennis, or volleyball, or
during training sessions related
thereto.
[00070] Accordingly, the adjustable helmet system with improved locking
mechanisms provide
significant benefits that can overcome some of the disadvantages of the
previous adjustable helmet
designs. The adjustable helmet system offers a two-piece shelled helmet that
allows adjustment and/or
locking of the helmet quickly and efficiently without the need for tools, it
allows the locking and/or
unlocking of the helmet with one handed function, it can allow for the impact
mitigation layers and/or
comfort liners pad systems to be easily disconnected and/or adjusted within
the helmet, and/or provide for
localized deflection through the incorporation of structural features that
promote the absorption of energy
from the impact in more predictable ways. The adjustability is key should the
players or wearers decide
to improve their impact protection during play, and exchange at least a
portion of the impact mitigation
layer and/or at least a portion of the supplemental layer based on the
frequency or severity of impact.
Then, the adjustable helmet system may be properly adjusted to accommodate the
comfort and sizing of
the specific wearer.
[00071] Adjustable Helmet Assembly
[00072] FIGS. 1A-1F depicts various views of one embodiment of an
adjustable helmet assembly
101. FIG. 1G depicts an exploded isometric view of the adjustable helmet
assembly 101. The adjustable
helmet assembly 101 comprises an adjustable helmet system 102, and an impact
mitigation layer 103.
The adjustable helmet assembly may further comprise at least one inner shell
104, a supplemental layer
105, an ear protection 106, an ear loop 107, a visor 108, a chinstrap (not
shown) and/or any combination
thereof
[00073] In one exemplary embodiment, the adjustable helmet assembly 101
comprises an
adjustable helmet system 102, an impact mitigation layer 103, an inner shell
104. The adjustable helmet
assembly 101 may further comprise a supplemental layer 105. The impact
mitigation layer 103 nests
within the adjustable helmet system 102, and the impact mitigation layer 103
disposed between the
adjustable helmet system 102 and the inner shell 104. The supplemental layer
105 nests within the inner
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shell 104, where an exterior surface of the supplemental layer 105 is adjacent
to an interior surface of the
inner shell 104.
[00074] Adjustable Helmet System
[00075] FIGS. 2A-2J depict various views of different embodiments of an
adjustable helmet
system 201. In one embodiment, the adjustable helmet system 201 may comprise a
front shell (or first
shell) 206, a back shell (or second shell) 202 and a locking mechanism 208.
The locking mechanism may
comprise a clamp lock mechanism and/or a cam lock mechanism. The locking
mechanism 208 further
comprising a clamp tongue 214, a clamp body 213 and a clamp recess 215. The
first 206 and/or second
shell 202 may be slidably connected, slidably coupled and/or rotatably coupled
together via the locking
and unlocking of the locking mechanism 208. More specifically, the locking
mechanism 208 being
movable between an unlocked position which allows the first 206 and second
shells 202 to slide relative
to each other and a locked position which prohibits the first 206 and second
shells 202 from sliding
relative to each other. The adjustable helmet system 201 may further comprise
additional features,
including helmet alignment guides 203, a side plate 204, ear protection 204, a
front plate 207, a center
plate 209, one or more openings 210, one or more crumple zones 211, one or
more securement holes 212
and/or any combination thereof.
[00076] The locking mechanism 208 may be a modular assembly and/or
integrated within the first
206 and/or second 202 shells. In one embodiment, the locking mechanism
comprises a clamp assembly, a
plurality of teeth, at least a portion of the plurality of teeth sized and
configured to fit within a portion of a
plurality of recesses, the plurality of teeth disposed on the first or second
shell, a plurality of recesses, at
least a portion of the plurality of recesses are sized and configured to
receive the plurality of teeth, the
plurality of recesses disposed on the first or second shell, the clamp
assembly being movable between an
unlocked position that allows the plurality of teeth and the plurality of
recesses to disengage and allows
the first and second shells to slide relative to each other, and a locked
position that allows the a portion of
the plurality of teeth and a portion of the plurality of recesses to engage
and inhibits the first and second
shells from sliding relative to each other.
[00077] The first 206 and/or second shell 202 may be manufactured from a
relatively rigid
material, such as polyethylene, nylon, polycarbonate materials, acrylonitrile
Butadiene Styrene (ABS),
polyester resin with fiberglass, thermosetting plastics, and/or any other
rigid thermoplastic materials.
Alternately, the first and/or second shell may be manufactured from a
relatively deformable material, such
as polyurethane and/or high-density polyethylene, where such material allows
local deformation upon
impact. FIGS. 5A-5G and FIGS. 38A-38I depict various views of an alternate
embodiments of an
adjustable helmet.
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[00078] FIGS. 3A-3F depict various views of one embodiment of a first
shell or front shell 301.
The first shell 301 may comprise a top portion 303, a front portion 302,
and/or side portions 304 (e.g.,
right and left sides). The front portion 302 is positioned within the frontal
region of a wearer's head and
may extend towards the rear or back of the wearer's head, covering at least
portions of top portion 303 or
the crown region and/or the right and left temporal regions of the wearer's
head or the side portions 304,
where the edge is at or immediately adjacent to the wearer's eyebrows. The
front portion 302 may
comprise a front plate 307 and securement holes 306 to secure the front plate
307 to the front portion 302.
The front plate 307 may be utilized as aesthetic feature and/or a logo may be
disposed onto the front plate.
Alternatively, the front plate 307 may comprise at least a portion of an
impact mitigation structure as
disclosed herein. The impact mitigation structure may be affixed to the first
shell 301 and the front plate
307 may be affixed to the impact mitigation structure and/or the first shell
301. The front plate 307 may
have securement holes 306 and/or other features to affix the front plate 307
to the first shell 301. The
securement holes 306 and/or features may comprise rivets, screws, snaps,
Velcro, adhesive, press fit,
and/or any combination thereof. The first shell 301 may further comprise a
plurality of openings 305,
where the openings may provide for ventilation and/or give rise to one or more
crumple zones 310. The
one or more openings 305, the one or more openings 305 being elongated and
having a width and a
length, the length being at least two times larger than the width. The one or
more openings 305 may
comprise one or more tabs (not shown) that span the width of the one or more
openings 305. FIGS. 39A-
39H depict various views of an alternate embodiment of a first or front shell.
[00079] The top portion 303 of the first or front shell 301 may be
positioned on a portion of a
central ridge of a wearer's head and covering a portion of the parietal region
of a wearers head as shown
as FIG. 3C-3D. The top portion 303 of the first or front shell 301 may
comprise a central plate 308, one
or more openings 305 and a portion of the lock mechanism, the central plate
308 having a perimeter edge
311, the perimeter edge 311 sits below the perimeter edge 312 of the top
portion 303, leaving an
indentation or recessed area disposed within the top portion 303. The top
portion 303 may further
comprise one or more openings 305, the one or more openings 305 being
elongated and having a width
and a length, the length being at least two times larger than the width. The
one or more openings 305
may further comprise one or more tabs (not shown) that spans the width of the
one or more openings 305.
Additionally, the central plate 308 includes a clamp tongue 313. The clamp
tongue 313 may be
positioned adjacent or proximate to the central plate 308 of the first or
front shell. The clamp tongue 313
being a longitudinal member having a first end and a second end, the first end
affixed to the central plate
308, and the second end extending away from the central plate 308 of the top
portion 303 of the first or
front shell 301 on a substantially similar planar surface or on the same plane
as the central plate 308.
Substantially similar may include an offset plane having a range of minus 20
to plus 20 degrees difference
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(or a 0.25 in to 2 in below the planar surface of the central plate 308) from
the co-planar surface of the
top portion 303 and/or the co-planar surface of the central plate 308 of the
first or front shell 301. The
clamp tongue 313 having a top surface 317, a bottom surface 316 and a first
channel 314. The clamp
tongue top surface 317 having a plurality of a plurality recesses 315 disposed
onto the top surface 317, at
least a portion of the plurality of recesses 315 are sized and configured to
receive a portion of a plurality
of teeth 413 (see FIG. 4D) and/or are sized and configured to engage a portion
of a plurality of teeth 413,
the first channel 314 sized and configured to receive a clamp post 420 (see
FIG. 4F). FIGS. 39E-39F
depict various views of an alternate embodiment of a top portion of a first or
front shell.
[00080] The side portions 304 of the first or front shell 301 may be
positioned within or near the
temporal regions of the wearer, covering the right and left sides of the
wearer and/or at least a portion of
the wearer's mandible as shown in FIG. 3E-3F. The side portions 304 may
comprise at least one side
plate (not shown), at least one side plate recess 318, one or more securement
holes 306, one or more
openings 305 and/or any combination thereof The side plate being disposed
within the side plate recess
318, and the securement holes 306 secure the side plate within the side plate
recess 318. The side portion
304 may further comprise or more openings 305, the one or more openings 305
being elongated and
having a width and a length, the length being at least two times larger than
the width. The top portion 303
may further comprise one or more tabs (not shown) that couple the central
plate 308 to the top portion
303. The one or more tabs (not shown) may span the width of the one or more
openings 318. The first
shell side portions 304 may further comprise an ear cover. The ear cover may
comprise a portion of the
shell that extends proximate to the wearer's ear for protection. The ear cover
may include holes for
further securement of a chin strap (not shown). In another embodiment, the
first shell side portion may
further comprise a side plate recess 318 and/or a side plate (not shown). The
side plate recess 318 may
be disposed on a portion of the first shell side portion 304, the side plate
recess 318 may be sized and
configured to receive the side plate. The side plate may be sized and
configured to fit within the side
plate recess 318. Alternatively, the side plate may be affixed to a portion of
the first shell side portion
304. The side plate may be utilized as aesthetic feature and/or a logo may be
disposed onto the side plate.
Alternatively, the side plate may comprise at least a portion of an impact
mitigation structure as disclosed
herein, the impact structure may be disposed within the side plate recess 318,
and the side plate positioned
over the impact structure. The side plate may have securement features to
affix the side plate to the first
shell 301. The securement features may comprise rivets, screws, snaps, Velcro,
adhesive, press fit and/or
any combination thereof FIGS. 39G-39H depict various views of an alternate
embodiment of a side
portion of a first or front shell.
[00081] FIG. 3F depicts a cross-sectional view of one embodiment of a side
portion 304 of the
first shell 301. The first shell 301 may further comprise one or more
alignment protrusions 319 that
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longitudinally extends perpendicular or substantially perpendicular from an
interior or exterior surface of
the side portion 304. Such one or more alignment protrusions 319 may be sized
and configured to fit
within one or more alignment protrusion channels 403. The alignment
protrusions 319 are inserted within
the one or more alignment protrusion channels 403 (see FIG. 4E) to allow the
first shell 301 and the back
shell 401 to mate and facilitate the proper alignment to slidably connect at a
fixed distance. The one or
more alignment protrusions 319 may be molded directly onto the first shell 301
and/or the one or more
alignment protrusions 319 may be affixed by a separate structure. The separate
structure may comprise a
base, and the one or more protrusions perpendicularly extending upwards from
the base, the base being
coupled to the first shell 301. The slidable fixed distance may range from 1
mm to 40 mm. The
alignment protrusion channels 403 having a width and length, the length of the
alignment protrusion
channel 403 being a range from 1 mm to 40 mm. The first shell 301 side portion
304 may further
comprise a plurality of openings 305, where the openings may provide for
ventilation and/or give rise to
one or more crumple zones. The one or more openings 305 being elongated and
having a width and a
length, the length being at least two times larger than the width. The side
portion 304 may further
comprise one or more tabs (not shown), the one or more tabs (not shown) may
span the width of the one
or more openings 305. FIG. 39H depicts a cross-sectional view of an alternate
embodiment of a side
portion of the first shell.
[00082] FIGS. 4A-4F depict various views of one embodiment of a second
shell, back shell or
rear shell 401. The second shell 401 may comprise a back portion 408, a top
portion 411 and/or a side
portion 419. In one embodiment, the second shell 401 may comprise a portion of
the lock mechanism
404, one or more openings 402 giving rise to one or more crumple zones 407, a
central plate 406, and one
or more alignment protrusion channels 403, and/or any combination thereof.
More specifically, FIG. 4B
illustrates a back view of one embodiment of a back portion 408 of the second
or back shell 401. The
back portion 408 may of the second or back shell 401 may comprise a central
plate 406, the central plate
406 having a perimeter edge 409, the perimeter edge 409 sits below the
perimeter edge 410 of the back
portion 408 of the second or back shell 401, leaving an indentation, depressed
or recessed area disposed
within the back portion 408 of the second or back shell 401. The central plate
406 may extend from the
lower occipital region (or lower back) up towards the mid-back region and to
the top portion 411 of the
second or back shell 401. The back portion 408 may further comprise one or
more tabs 405 that couple
the central plate 406 to the back portion 408 of the second or back shell 401.
FIGS. 40A-40G depict
various views of an alternate embodiment of a second or back shell, and
specifically, FIGS. 40C-40D
depict a front and back view of an alternate embodiment of a back portion of a
second or back shell.
[00083] FIGS. 4C-4D illustrate the top and bottom view of one embodiment
of a top portion 411
of the second or back shell 401. The top portion 411 of the second or back
shell 401 covering at least a
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portion of the crown region of the head and extends towards a portion the back
portion that covers the
occipital and/or the temporal region of the head. The top portion 411 of the
second or back shell 401 may
comprise a central plate 406 and a portion of the lock mechanism 404, the
central plate 406 having a
perimeter edge 409, the perimeter edge 409 sits below the perimeter edge 410
of the top portion 411,
leaving an indentation or recessed area disposed within the top portion 411 of
the second or back shell
401. The top portion 411 may further comprise one or more tabs 412 that couple
the central plate 406 to
the top portion 411 of the second or back shell 401. Additionally, the central
plate 406 includes a portion
of a lock mechanism 404, the lock mechanism comprising a plurality of teeth
414. The central plate 406
may further comprise a central plate external surface 417 and a central plate
internal surface 418, the
central plate external surface 417 having a recess 413, the recess extending
from the central plate external
surface 417 towards the central plate internal surface 418. The recess 413
further comprising a recess
external surface 412 and a recess internal surface 415. The recess internal
surface 415 comprising a
plurality of teeth 414, the plurality of teeth 414 perpendicularly extending
away from the recess internal
surface 415. The plurality of teeth 414 having different cross-sectional
shapes and configurations, the
shapes and configurations of the plurality of teeth 414 to be sized to fit
within a portion of the plurality of
recesses 315 of the clamp tongue 313. FIGS. 40C-40D depict atop and bottom
view an alternate
embodiment of a top portion of a second or back shell.
[00084] Furthermore, the recess external surface 415 of the top portion
411 of the second or back
shell 401 may further comprise a clamp post 420. The clamp post 420 being a
solid or hollow
longitudinal member that perpendicularly extends from the recess external
surface 415. The clamp post
420 being a longitudinal member having a diameter, a height, a first end and a
second end. The first or
second end being coupled to the recess external surface 415, and the first or
second having a planar
surface, the planar surface abutting or mating within a planar surface of the
clamp body. The recess 413
comprising a cross-sectional shape and a height 421. The recess 413 cross-
sectional shape is configured
to match or substantially match the clamp body (not shown) of the locking
mechanism 404. The recess
height 421 being equal to a clamp body width to provide a flush surface, or
the recess height being greater
than the clamp body width to allow the clamp body to be slightly recessed.
Accordingly, the top portion
411 of the second or back shell 401 comprises one or more openings 402 giving
rise to one or more
crumple zones 407. FIGS. 40E-40F depict a top and bottom view an alternate
embodiment of a top
portion of a second or back shell.
[00085] The side portions 419 of the second or back shell 401 may be
positioned within or near
the temporal regions of the wearer, covering the right and left sides of the
wearer and/or at least a portion
of the wearer's mandible as shown in FIG. 4E-4F. The side portions 410 of the
second or back shell 401
may comprise one or more alignment protrusion channels 403, one or more
openings 402 that gives rise
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to one or more crumple zones 407, and/or any combination thereof The one or
more alignment protrusion
channels 403 may be molded directly onto the second shell 401 and/or the one
or more alignment
protrusion channels 403 may be affixed by a separate structure 3703 as shown
in FIGS. 37A-37B. The
separate structure 3703 may comprise a base 3704, and the one or more
protrusion channels 3705
extending through the base 3704, the base 3704 being coupled to the second
shell 3702, allowing the
protrusions 318 (see FIG. 3F) to be inserted into the one or more protrusion
channels 3705 for controlled
sliding and controlled distance. The second shell side portions 419 may
further comprise a portion of the
ear cover. The ear cover may comprise a portion of the shell that extends
proximate to the wearer's ear
for protection. The ear cover may include holes for further securement of a
chin strap (not shown). The
alignment protrusions 319 (see FIG. 3F) are inserted within the one or more
alignment protrusion
channels 403 to allow the first shell 301 and the back shell 401 to mate and
facilitate the proper alignment
to slidably connect at a fixed distance. The slidable fixed distance may range
from 1 mm to 40 mm. The
alignment protrusion channels 403 having a width and length, the length of the
alignment protrusion
channel 403 being a range from 1 mm to 40 mm. The second shell 401 side
portion 419 may further
comprise a plurality of openings 402, where the openings may provide for
ventilation and/or give rise to
one or more crumple zones 407. FIG. 40G depicts a side view of alternate
embodiment of a side portion
of a second or back shell.
[00086]
Alternatively, the protrusion alignment channels or the alignment guides 403
and the
alignment protrusions 319 may be switched. For example, the protrusion
alignment channels 403 may be
disposed on the first shell 301 rather than the second shell 401. Accordingly,
the alignment protrusions
319 may be disposed on the second shell 401 rather than the first shell 301.
The helmet alignment guides
or alignment protrusion channels may be strategically placed onto or within
any region of the helmet,
including frontal, ridge (or top), and/or the sides (right or left). The
helmet alignment guides will help
align the front and back shells in the proper position during adjustment. The
helmet alignment guides
comprise alignment protrusions and alignment guide channels. The alignment
protrusions may be
disposed onto a least a portion of the first or second shell, the alignment
protrusions being sized and
configured to fit within the alignment guide channels. The alignment guide
channels may be disposed
onto a least a portion of the first or second shell, the alignment guide
channels having a translation length,
the translation length minimizing the total adjustment size of the helmet. The
alignment guide channels
being sized and configured to receive the alignment protrusions. Once the
alignment protrusions mate
with the alignment guide channels, the helmet may only be adjusted to the
designed translation length.
The translation length may be anywhere from 0 inches to 6 inches.
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[00087] Locking Mechanism Assemblies
[00088] In one embodiment, an adjustable helmet system may comprise a
locking mechanism, the
locking mechanism being a clamp locking mechanism assembly 601 (see FIGS. 6A-
6B, FIGS. 17A-17D,
FIGS. 18A-18D, and FIG. 381) or a cam locking mechanism assembly 1101 (see
FIGS. 11A-11J). The
locking mechanism may be integrated within a portion of the front or back
shells and/or be modular,
which the modularity allows the locking mechanism to be retrofitted to
commercially available helmets.
The locking mechanism being movable between a first unlocked position which
allows the first (or front)
and second (or back) shells to slide relative to each other and a second
locked position which inhibits the
first and second shells from sliding relative to each other.
[00089] FIGS. 6A-6H, FIGS. 17A-17B and FIGS. 381 depict various views of
an alternate
embodiment of a clamp locking mechanism assembly. More specifically, FIGS. 6A-
6H depicts one
embodiment of a clamp locking mechanism assembly 601 that comprises at least
one clamp lock
subassembly 603 and a clamp tongue 602. The clamp locking assembly 601 will
facilitate easy no-tool
detachment and securement by using a lever function and may require only a one-
handed operation. For
example, FIGS. 17A-17D illustrate an example of a method to adjust a
representative adjustable helmet
assembly 1701. The user or wearer may lift the clamp body 1705 allowing the
clamp post 1705 to place a
downward compressive force against a portion of the first or second shells
1702, 1703 thereby releasing
the first and/or second shells 1702, 1703 to move relative to each other.
Conversely, to secure or lock the
clamp locking assembly 1703, the user or wearer will push the clamp body down
1705 within the cavity
allowing the base plate 1707 coupled to the clamp post 1707 to place an upward
compressive force to
sandwich the at least a portion of the first and second shells 1702, 1703
and/or the clamp tongue 1708 and
have the plurality of teeth engage with the plurality of recesses to prevent
or inhibit movement of the first
and second shells 1702, 1703. FIGS. 17A-B and FIG. 381 illustrate cross-
sectional views of an alternate
embodiment of a clamp locking mechanism assembly.
[00090] FIGS. 61-61 illustrate an exploded isometric view of a clamp
locking mechanism 601.
The clamp locking mechanism assembly 601 may comprise at least one clamp lock
subassembly 603 and
a clamp tongue 602. The clamp lock subassembly 603 comprises at least one of a
clamp housing 608, a
clamp body 607, clamp post 604, and/or a base plate 609. The clamp lock
subassembly 603 may further
comprise a spring (not shown). Alternatively, FIGS. 381 illustrate an exploded
side view of a clamp
locking mechanism assembly 3801. The clamp locking mechanism assembly 3801
comprises a clamp
body 507, a plurality of teeth 3804, a plurality of recesses (not shown), and
a clamp post 3805. The
plurality of recesses being disposed an external surface of a clamp tongue
3803.
[00091] FIGS. 7A-7H depict various views of one embodiment of a clamp
housing 701. The
clamp housing 701 comprises a clamp housing recess 703 and a plurality of
teeth 708. The clamp
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housing 701 having a top surface 702 and a bottom surface 709, at least a
portion of the top surface
having a clamp housing recess 703 or cavity extending from the top surface 702
below the bottom surface
709, the cavity or clamp housing recess 703 sized and configured to receive
the clamp body 607 (as
shown in FIGS. 6I-6J), the cavity or champ housing recess 703 having an
aperture 704, the aperture 704
extends through the clamp housing recess top surface 705 to the clamp housing
recess bottom surface
707, the aperture 704 having a width, the width matches or substantially
matches a width of a clamp post
604 (as shown in FIGS. 6I-6J). The clamp housing recess bottom surface 707 of
the clamp housing 701
having a plurality of teeth 708, the plurality of teeth 708 perpendicularly
extending outwardly from the
clamp housing bottom surface 707, the plurality of teeth 708 sized and
configured to fit within a portion
of a plurality of recesses 1002 on a clamp tongue 1001 (see FIGS. 10A-10H).
Alternatively, the clamp
housing 701 and the clamp tongue 1001 (see FIGS. 10A-10H) may reverse some of
the engagement
features. The clamp housing recess bottom surface 707 may alternatively
comprise a plurality of recesses
that are sized and configured to receive a plurality of teeth. Furthermore,
the clamp housing recess 703
having a clamp recess height (not shown), the clamp recess height is equal to
or greater than a clamp body
height 807 (see FIG. 8E). The clamp housing 701 may be affixed to the first or
second shell and/or it may
be integrated within the first or second shell. Desirably, should the clamp
housing 701 be integrated
within the first or second shell, the clamp housing 701 would be a recessed
surface disposed onto an
external surface of the first or second shell.
[00092] FIGS. 8A-8H and 9A-9G depict various views of one embodiment of a
clamp body 801
and a clamp post 901. The clamp body 801 comprises a lever portion 805, at
least one finger tab 805, a at
least one base portion 804, an aperture 803, and/or any combination thereof
The clamp body 801 is sized
and configured to fit within and/or disposed within the clamp housing cavity
or the clamp housing recess
703 (see FIG. 7B). The at least one finger tab 805 extends longitudinally from
the lever portion 805, the
longitudinal extension is on a plane that is parallel and/or substantially
parallel to the lever portion 805.
The at least one base 804 having a base channel 806 that extends
perpendicularly through the at least one
base 804. The base channel 806 having a base channel width 808 that matches or
substantially matches
the clamp post width top portion 906 of the clamp post top portion 902. The
clamp body further
comprising a clamp body aperture 803, the clamp body aperture 803 aligns with
the clamp post aperture
904 or is concentric with the clamp post aperture 904. The clamp post 901
being pivotally connected to
the clamp body 801 allowing for a lever action or function.
[00093] FIGS. 16A-16F and FIGS. 41A-41G depict various views of an
alternate embodiment for
a clamp body. More specifically, FIGS. 41A-41G depict a clamp body 4101, the
clamp body 4101
comprises a lever portion 4102, a base 4103, at least one aperture 4104, and
at least one channel 4108.
The clamp body 4101 is sized and configured to fit within and/or disposed
within the clamp housing
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cavity or the clamp housing recess 703 (see FIG. 7B). The lever portion 4102
of the clamp body 4101
having a plurality struts that form a matrix or a framework to provide support
to the clamp body 4101 and
to resist compression or other impacts. Each of the plurality struts are an
elongated column. A first
plurality of struts are positioned longitudinally along an axis of the clamp
body 4101, and a second
plurality of struts are positioned perpendicular to the longitudinal axis of
the clamp body 4101. The at
least one base 4103 having a base channel 4105 that extends perpendicularly
through the at least one base
4103. The at least one base 4103 extending perpendicularly below the lever
portion 4102. The base
channel 4105 having a base channel width 4106 that matches or substantially
matches the clamp post
width 4206 first end 4204 of the clamp post top portion 4202. The clamp body
further comprising a
clamp body aperture 4104, the clamp body aperture 4104 aligns with the clamp
post aperture 4209 or is
concentric with the clamp post aperture 4209. The clamp post 4201 being
pivotally connected to the
clamp body 4101 allowing for a lever action or function.
[00094] FIGS. 9A-9G illustrates various views of one embodiment of a clamp
post 901. The
clamp post 901 comprising a clamp post top portion 902 and a clamp post bottom
portion 903. The
clamp post top portion 902 and the clamp post bottom portion 903 having a
cross-sectional shape. The
cross-sectional shape is circular, and/or it may be hollow. Other cross-
sectional shapes may be
contemplated, including square and rectangular. The clamp post having a T-
shape, where the clamp post
top portion 902 is perpendicular to the clamp post bottom portion 903 forming
the T-shape. The clamp
post 901 having an end with a planar surface 905, the planar surface abuts or
is coupled to the base plate
(not shown).
[00095] FIGS. 42A-42H illustrates various views of an alternate embodiment
of a clamp post
4201. The clamp post 4201 comprising a clamp post top portion 4102 and a clamp
post bottom portion
4203. The clamp post top portion 4202 and the clamp post bottom portion 4203
having a cross-sectional
shape. The clamp post top portion 4202 cross-sectional shape is generally
rectangular. The clamp post
top portion 4202 extends perpendicular to the base 4203. The clamp post top
portion 4202 having a first
end 4204 and a second end 4205, the second end 4205 coupled to the clamp post
bottom portion 4203.
The first end 4204 having a cylindrical shape, the first end 4204 having a
width 4206. The width 4206 of
the first end 4204 of the clamp post top portion 4202 that matches or
substantially matches the base
channel 4105 of the clamp body 4101 (see FIGS. 41A- 41G). The clamp post
bottom portion 5203 cross-
sectional shape is rectangular or generally rectangular, but other shapes may
be contemplated, including
square, circular or triangular. The clamp post bottom portion 5203 having a
first surface 4207 and a
second surface 4208, the second surface 4208 having a plurality of ribs 4209
extending along at least a
portion of the length of the clamp post bottom portion 4203. The plurality of
ribs 4209 extending parallel
or perpendicularly below the second surface 4208. The first surface 4207 abuts
and/or mates with at least
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a portion of the first surface 1004 or second surface 1005 of the clamp tongue
1001 (see FIGS. 10A-10H
or 381) and/or the bottom surface of a clamp tongue.
[00096] FIG. 10A-10H depicts various views of an alternate embodiment of a
clamp tongue 1001.
The clamp tongue 1001 having a longitudinal body, at least a portion of the
longitudinal body angled
obliquely between a range of 1 degree to 60 degrees. The clamp tongue having a
first surface 1004 and a
second surface 1005, at least a portion of the first surface 1004 or second
surface 1005 including a
plurality recesses 1002, the plurality of recesses 1002 sized and configured
to receive a portion of the
clamp housing plurality of teeth 703 (see FIG. 7A), the clamp tongue 1001
further comprising a clamp
tongue channel 1003, the clamp tongue channel 1003 extends through the first
surface 1004 to the second
surface 1005, the clamp tongue channel 1003 having a clamp channel width 1006,
the clamp channel
width 1006 being sized and configured to receive the clamp post bottom portion
903 (see FIGS. 9A-9G)
and/or the clamp channel width 1006 matching or substantially matching the
clamp post bottom portion
width and/or cross-sectional shape. The clamp channel 1003 having a channel
length 1007, the channel
length 1007 allowing clamp post 901 to translate axially, the translation
distance being 1 mm to 25 mm.
The clamp post coupled to a base plate.
[00097] Alternatively, the clamp housing 701 (see FIG. 7A-7H) and the
clamp tongue 1001 (see
FIGS. 10A-10H) may reverse some of the engagement features. The clamp housing
recess bottom
surface 707 may alternatively comprise a plurality of recesses that are sized
and configured to receive a
plurality of teeth. Furthermore, the clamp housing recess 703 having a clamp
recess height (not shown),
the clamp recess height is equal to or greater than a clamp body height 807
(see FIG. 8E). The clamp
housing 701 may be affixed to the first or second shell, and/or the clamp
tongue 1001 may be affixed to
the first or second shell. The clamp tongue 1001 having a first surface 1004,
a second surface 1005 and a
clamp channel 1003. The clamp tongue first surface 100 having a plurality of a
plurality teeth 703
disposed onto the first surface 1004, at least a portion of the plurality of
recesses 1002 disposed on the
clamp housing 701 are sized and configured to receive a portion of a plurality
of teeth 703, the clamp
channel 1003 sized and configured to receive a clamp post 901.
[00098] FIGS. 11A-11H depicts various views of one embodiment of a cam
locking mechanism
assembly 1101. The adjustable helmet system may comprise a first shell, a
second shell and a locking
mechanism assembly, the locking mechanism assembly comprises a cam locking
mechanism 1101. The
cam locking mechanism 1101 may comprise a cam tongue 1102 and a cam locking
subassembly 1103.
The cam locking assembly 1101 will facilitate easy no-tool detachment and
securement by using a
rotation action and may require only a one-handed operation. To adjust a
representative helmet, the user
or wearer may rotate the cam body allowing the cam post to place a downward
compressive force against
a portion of the first or second shells thereby releasing the first and/or
second shells to move relative to
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each other. Conversely, to secure or lock the cam locking assembly, the user
or wearer will rotate the
cam body in the opposite direction allowing the base plate coupled to the cam
post to place an upward
compressive force to sandwich the at least a portion of the first and second
shells and prevent or inhibit
movement and have the plurality of teeth engage with the plurality of
recesses.
[00099] FIGS. 11I-11J depict an exploded isometric and side view of one
embodiment of a cam
lock mechanism 1101. The cam lock mechanism 1101 comprises a cam tongue 1102
and a cam locking
subassembly 1103. The cam locking subassembly 1103 comprises a cam housing
1104, a cam post 1105,
a base plate 1107, a cam body 1106, and/or any combination thereof
[000100] FIGS. 12A-12H depict various views of one embodiment of a cam tongue
1201. The
cam tongue 1201 having a longitudinal body, at least a portion of the
longitudinal body having an arched
shape or a generally arched shape. The cam tongue 1201 having a first surface
1202 and a second surface
1203, at least a portion of the first surface 1202 or second surface 1203
including a plurality recesses
1204, the plurality of recesses 1204 sized and configured to receive a portion
of the cam housing plurality
of teeth 1303 (see FIG. 13A), the cam tongue 1201 further comprising a clamp
tongue channel 1205, the
cam tongue channel 1205 extends through the first surface 1202 to the second
surface 1203, the cam
tongue channel 1205 having a cam channel width 1206, the cam channel width
1206 being sized and
configured to receive the cam post top portion 1402 (see FIGS. 14A-14G) and/or
the cam channel width
1206 matching or substantially matching the cam post top portion width and/or
cross-sectional shape.
The cam channel 1203 having a channel length 1207, the channel length 1207
allowing cam post 1401 to
translate axially, the translation distance being 1 mm to 25 mm. The cam post
coupled to a base plate.
The cam tongue 1201 may be positioned and/or coupled on the top portion of the
front or back shell, and
extend longitudinally away from the top portion of the front or back shell.
[000101] Alternatively, the cam tongue 1201 and/or the front or back shells
may reverse some of
the engagement features. The cam tongue 1201 having a first surface 1202 and a
second surface 1203, at
least a portion of the first surface 1202 including the plurality teeth, the
plurality of teeth sized and
configured to fit within a plurality of recesses with a front or back shell
top portion second surface, the
cam tongue having a channel 1203, the channel 1203 extends through the first
surface 1202 to the second
surface, the channel 1203 sized and configured to receive the cam post 1401;
the channel having a length,
the length allowing cam post 1401 to translate along an axis.
[000102] FIGS. 13G-13H depict various views of one embodiment of a cam housing
1301. The
cam housing 1301 comprises a clamp housing recess 1302 and a plurality of
teeth 1203. The cam
housing 1301 having a top surface 1304 and a bottom surface 1305, at least a
portion of the top surface
1304 having a cam housing recess 1302 or cavity starting from the top surface
1304 and extending below
the bottom surface 1305, the cavity or cam housing recess 1302 sized and
configured to receive the cam
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body 1501 (as shown in FIGS. 15A-15H), the cavity or cam housing recess 1302
having an aperture
1306, the aperture 1306 extends through the cam housing recess top surface
1307 to the cam housing
recess bottom surface 1308, the aperture 1306 having a width, the width
matches or substantially matches
a width of a cam post top portion 1402 (as shown in FIGS. 14A-14H). The cam
housing recess bottom
surface 1308 of the cam housing 1301 having a plurality of teeth 1303, the
plurality of teeth 1303
perpendicularly extending outwardly from the cam housing bottom surface 1308,
the plurality of teeth
1303 sized and configured to fit within a portion of a plurality of recesses
1002 on a cam tongue 1301
(see FIGS. 10A-10H).
[000103] Alternatively, the cam housing 1301 and the camp tongue 1201 (see
FIGS. 12A-12H)
may reverse some of the engagement features. The cam housing recess bottom
surface 1308 may
alternatively comprise a plurality of recesses 1204 (see FIG. 12A-12H) that
are sized and configured to
receive a plurality of teeth 1303. Furthermore, the cam housing recess 1302
having a cam recess height
(not shown), the cam recess height is equal to or greater than a cam body
height 1507 (see FIG. 15F).
The cam housing 1301 may be affixed to the first or second shell.
[000104] FIGS. 14A-14H depict various views of one embodiment of a cam post
1401. The cam
post 1401 comprising a cam post top portion 1402 and a cam post bottom portion
1403. The cam post top
portion 1402 having a cam post top portion cross-sectional shape. The cam post
top portion cross-
sectional shape includes circular, and/or it may be hollow. Other cross-
sectional shapes may be
contemplated, including square and rectangular. The cam post top portion 1402
may have a channel 1404
that extends from the first end 1405 of the cam post top portion 1402 towards
a portion of the second end
1406 of the cam post top portion 1402. At least a portion of the channel 1404
may be chamfered. The
cam post having a T-shape, where the cam post top portion 1402 is a
longitudinal member that
perpendicularly extends upward from the cam post bottom portion 1403 forming
the T-shape. The cam
post second end 1406 having an end with a planar surface, the planar surface
abuts or is coupled to the
cam post bottom portion 1403.
[000105] FIGS. 15A-15H depict various views of one embodiment of a cam body
1501. The cam
body 1501 comprises a first portion 1502, a second portion 1503, an aperture
1504, and/or any
combination thereof The cam body 1501 is sized and configured to fit within
and/or disposed within the
cam housing cavity or the clamp housing recess 1302 (see FIG. 13B). The first
portion abuts or mates
with the cam housing top surface 1307. The second portion 1503 having a
longitudinal member that
extends perpendicularly first portion 1502. The second portion 1503 may
further comprise atop surface,
the top surface having a recess 1506 disposed within. The second portion 1503
may further comprise ribs
1504, the ribs 1504 having a generally triangular shape. Other shapes may be
contemplated, including
square or rectangle. The ribs 1504 are intended to allow the wearer to have
sufficient surface area to hold
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the cam body 1501 and rotate. The aperture 1504 having a width that matches or
substantially matches
the cam post width top portion 1402 of the cam post 1401. The cam post 1501
being inserted to the cam
body 1401 allowing for a rotation action or function.
[000106] In another embodiment, the adjustable helmet system may have an
alternate embodiment
of an integrated locking mechanism. The adjustable helmet comprises a first
shell, the first shell having
an external surface and an internal surface; a second shell, the second shell
being slidably attached to the
first shell, the second shell an external surface and an internal surface; and
a locking mechanism, the
locking mechanism including: a clamp tongue, clamp tongue extending away from
the first or second
shell, the clamp tongue having a plurality of a plurality recesses, at least a
portion of the plurality of
recesses are sized and configured to receive a portion of a plurality of
teeth; a plurality of teeth, at least a
portion of the plurality of teeth sized and configured to fit within a portion
of the plurality of recesses, the
plurality of teeth disposed on a portion of the first or second shell internal
surfaces; and a clamp
assembly, the clamp assembly being movable between a unlocked position that
disengages the portion of
the plurality of teeth from the portion of the plurality of recesses and allow
the first and second shells to
slide relative to each other, and a locked position that allows the a portion
of the plurality of teeth and a
portion of the plurality of recesses to engage that inhibits the first and
second shells from sliding relative
to each other. The adjustable helmet may further comprise a cavity, the cavity
being sized and configured
to receive the clamp assembly, the cavity being disposed within the first or
second shells, the clamp
assembly having a top surface and a bottom surface, the clamp assembly top
surface being flush or
substantially flush with the external surface of the first or second shell.
[000107] In another embodiment, the adjustable helmet system may have an
alternate embodiment
of an integrated locking mechanism. An adjustable helmet comprising: a first
shell, the first shell having
an external surface and an internal surface; a second shell, the second shell
being slidably attached to the
first shell, the second shell an external surface and an internal surface; and
a locking mechanism, the
locking mechanism including; and a clamp assembly, the clamp assembly having a
clamp body, the
clamp post, and a base plate; a clamp tongue, clamp tongue extending away from
the first or second shell,
the clamp tongue having a top surface, a bottom surface and a first channel,
the clamp tongue top surface
having a plurality of a plurality recesses, at least a portion of the
plurality of recesses are sized and
configured to receive a portion of a plurality of teeth, the channel sized and
configured to receive the
clamp post; a plurality of teeth, the plurality of teeth disposed on a portion
of the first or second shell
internal surface, at least a portion of the plurality of teeth sized and
configured to fit within a portion of
the plurality of recesses, the first or second shell internal surface further
including a second channel, the
second channel sized and configured to receive the clamp post; a cavity, the
cavity being sized and
configured to receive the clamp assembly, the cavity being disposed within the
first or second shells
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external surface, the clamp assembly having a top surface and a bottom
surface, the clamp assembly top
surface being flush or substantially flush with the external surface of the
first or second shell, the cavity
having an aperture, the aperture sized and configured to receive the clamp
post; the base plate coupled to
the clamp post, the base plate abuts the bottom surface of the clamp tongue; a
clamp assembly, the clamp
assembly being movable between a locked position and an unlocked position, the
locked position places
tension on the clamp post and the base plate to compress the clamp tongue
allowing a portion of the
plurality of teeth and a portion of the plurality of recesses on the clamp
tongue to engage and inhibit the
first and second shells from sliding relative to each other, the unlocked
position places compression on
the clamp post and the base plate to release the clamp tongue allowing the
portion of the plurality of teeth
and the portion of the plurality of recesses of the clamp tongue to disengage,
and allow the first and
second shells to slide relative to each other.
[000108] Ear Protection and Other Accessories
[000109] FIGS. 1A-1G and 19 depict different embodiments of adjustable helmet
assemblies that
include ear protection 1901. In one embodiment, adjustable helmet system may
further comprise ear
protection 1901. The ear protection 1901 may comprise a base 1905 and an ear
frame 1902. The base
1905 may have an exterior surface 1907 and an interior surface 1906. The ear
frame 1902 having a shape
that relatively matches or substantially matches or matches the wearer's ear.
The ear frame 1902 may
extend perpendicularly away from the base 1905 exterior surface 1907 to have a
slight protrusion. The
ear frame 1902 may include a recessed perimeter 1903, where the recessed
perimeter 1903 may relatively
matches or substantially matches or matches the wearer's ear, and the wearer's
ear may be seated or abut
against the recessed perimeter 1903. The ear frame 1902 may further comprise
an aperture 1908
therethrough, the aperture 1908 is sized and configured to substantially match
or reasonably match around
a wearer's ear canal to allow sound to easily penetrate and pass through. At
least a portion of the ear
protection 1901 is coupled to a first shell, and at least a portion of the ear
protection 1901 is coupled to a
second shell. Alternatively, the ear protection 1901 may be coupled to the
first or second shell. Ear
protectors may general offer protection around the temporal region of the
wearer's head. FIGS. 43A-43F
depict various views of an alternate embodiment of an ear protection.
[000110] FIGS. 1A-1G and FIG. 44A-44F depict an exploded view of an adjustable
helmet
assembly that comprises an ear loop. In one embodiment, the adjustable helmet
system may further
comprise an ear loop 4401. The ear loop 4401 may comprise a frame that extends
away from the edge of
the helmet downwards away from the ear towards the jaw and/or mandible region
of the wearer's head to
overlap a portion of the jaw and/or mandible region. The ear loop 4401 may
follow the contours of the
jaw and/or mandible region of the wearer's head. Such ear loop 4401 comprises
a first member 4402 and
a second member 4403, the first 4402 and second 4403 member having a length,
the length being average
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or median jaw length. The first member 4402 may be coupled to the first or
second shell (not shown), the
second member 4403 may be coupled to the first or second shell (not shown).
Each of the first member
4402 and the second member 4403 having first end and a second end. Each of the
first member 4402 and
the second member 4403 first end 4404, 4405 having a connecting structure
4406, the connecting
structure 4406 having a square or rectangle cross-sectional shape, the
connecting structure 4406 have a
width greater than the first member 4402 and the second member 4403 width.
Furthermore, the second
ends of the first member 4402 and the second member 4403 being coupled
together. The ear loop 4401
may be fixed, and/or removably connected. The ear loop 4401 is generally U-
shaped. The ear loop may
further comprise a pad. The pad may comprise at least one foam layer. The pad
may further comprise an
impact mitigation structure.
[000111] FIGS. 1A-1G depict an exploded view of an adjustable helmet assembly
that further
comprises a chin strap. Such chin strap may allow the wearer's head to be
secured to the helmet to
prevent premature dislodgement of the helmet during impact. The chin strap may
be removably coupled
to the first and/or second shells. The chin strap may further comprise a pad.
The pad may comprise at
least one foam layer. The pad may further comprise an impact mitigation
structure.
[000112] FIGS. 1A-1G depict an exploded view of an adjustable helmet assembly
that further
comprises a visor. Such visor may be affixed to the first and/or second shell
to protect players from glare
or eye injuries. Furthermore, the visor may comprise protective coatings, such
as scratch-resistance, UV
coating, anti-glare coating, and/or any combination thereof
[000113] Openings and Crumple Zones
[000114] In one exemplary embodiment, the adjustable helmet assembly may
comprise one or
more openings that gives rise to one or more crumple zones. Crumple zones are
areas of the adjustable
helmet assembly that are designed to deform in a controlled manner during an
impact. The specifically
designed crumple zones would absorb some of the impact force and redistribute
the impact force before
its transmitted to the wearer. More specifically, there's a given amount of
force present during any
impact, and the forces are determined by the acceleration and the mass of the
wearer or the objects
causing the impacts. Therefore, in order for the crumple zones to absorb and
redistribute the impact force,
it may do this by slowing down the acceleration or by extending the distance
over which the adjustable
helmet's kinetic energy is transferred out (into potential or thermal energy).
The acceleration may be
slowed by creating one or more crumple zones around the perimeter of the
adjustable helmet, which the
crumple zones would take the initial impact, slowing down acceleration by a
few tenths of a second to
create a drastic reduction in the force involved during an impact.
Accordingly, crumple zones may be
manufactured and integrated directly into the adjustable helmet and/or be
commercially available (CA)
helmet may be retrofitted with crumple zones.
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[000115] FIGS. 20A-20I depict one various views of alternate embodiments of an
adjustable
helmet 2001 with integrated crumple zones. In one embodiment, the adjustable
helmet 2001 may
comprise one or more openings 2002, 2003 that may be disposed onto a front
shell 2004 and/or a back
shell 2005. Such one or more openings 2002, 2003 may align with the front
shell 2004 and/or a back
shell 2005. Such one or more openings 2002, 2003 may an elongated cross-
sectional shape, such that
each of the one or more openings 2002, 2003 have a length and a width. The
length and/or the width of
the one or more openings 2002, 2003 may allow particular regions and/or
localized regions of the
adjustable helmet 2001 to bend, deflect and/or collapse as shown in FIGS. 20D-
201. The width may be a
range between 0.0625 inches to 2 inches, and the length may have a range
between 0.25 inches to 5
inches. The elongated cross-sectional shape of the one or more openings 2002,
2003 may follow the
contours of helmet. For example, in one embodiment, a unilateral or bilateral
lateral force 2010 may
impact the adjustable helmet 2001 leading to a localized bending and/or
deflecting 2011 one or both sides
of the adjustable helmet 2001 as shown in FIGS. 20D-20E. In another
embodiment, a normal or axial
force 2012 may impact the adjustable helmet 2001 leading to a localized
bending, deflecting, collapse
and/or buckling 2013 of the specific regions of the adjustable helmet 2001 as
shown in FIGS. 20F-20G.
Accordingly, in another embodiment, an oblique force 2014 may impact the
adjustable helmet 2001
leading to a localized bending, deflecting, collapse and/or buckling 2015 of
the specific regions of the
adjustable helmet 2001 as shown in FIGS. 20H-201.
[000116] The at least one opening 2002, 2003 placed adjacent to, in proximity
to or within impact
zones and/or crumple zones of the first shell 2004 or second shells 2005
resulting in absorption of the
energy from the impact by controlled local deformation and/or reducing the
impact forces transferred to
the head of the wearer. The impact zones are zones of a wearer's head that may
see higher than normal
frequency of impacts and/or magnitude of impacts. The impact zones are within
the occipital region
(lower and mid), temporal region (right and left side), parietal region, orbit
region, the frontal region, the
mandible (front, right and/or left side) region, the maxilla region, the nasal
region, zygomatic region, the
ethmoid region, the lacrimal region, the sphenoid region, crown region or top
ridge, raised eyebrow
region and/or any combination thereof. In addition, the at least one opening
may provide ventilation
allowing air to circulate around the head of the wearer. The at least one
opening may be positioned in
plane tangent to the helmet circumference, in a plane perpendicular or
substantially perpendicular to the
helmet circumference, or in an oblique plane to the helmet plane, in a plane
parallel to helmet plane,
and/or any combination thereof.
[000117] Furthermore, the one or more openings 2002, 2003 may have one or more
tabs 2006
disposed within the one or more openings 2002, 2003 to further absorb the
impact forces. The one or
more tabs 2006 couple the center plate 2007 to the top portion 2008 of the
front shell 2004 and/or the
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back shell 2005. The one or more tabs 2006 may be desirably used to provide a
controlled deformation
and/or buckling. The one or more tabs 2006 may span the width of the one or
more openings 2002, 2003.
The one or more tabs 2006 may have a length, width and depth, as well as a
cross-sectional shape that
facilitates a controlled deformation response by providing some relative
resistance. Such cross-sectional
shape can vary, and includes square, rectangle, triangle, hexagon, dome or
arched cross-sectional shape,
and/or any combination thereof. The desired cross-sectional shape would
improve on the specific
deformation properties that are expected for the adjustable helmet design. The
length, width and/or depth
of the one or more tabs 2006 may vary to obtain the ideal tab structure that
can provide such controlled
deformation, and still allow return to its original configuration.
Alternatively, different protrusions 2009
may be positioned within the center plate 2007 and/or other locations on the
adjustable helmet 2001 that
may also further facilitate impact absorption.
[000118] FIGS. 22A-22B, 23, 24A-24F, 25, 26A-26B and 27 depict various views
of alternate
embodiments of helmets with retrofitted crumple zones. Various types of
traditional commercially
available (CA) helmets 2101 have very pronounced shell features that are
purely aesthetic. Many of
these features contain shell protrusions 2102 on the outer helmet layer or
shell as shown in FIGS. 21A-
21F, where the shell protrusions 2102 may have an empty cavity that faces
internally towards the
wearer's head and protrude outwardly away from the exterior surface of the
outer shell. The CA helmets
2101 may have at least one shell protrusion 2102 with empty cavities are in
various regional locations that
are configured in varying sizes and shapes throughout the helmet outer layer
structure.
[000119] Furthermore, the shell protrusions 2102 provide many disadvantages to
the player that
decides to wear such a CA helmet 2101. The disadvantages provide (1)
additional unnecessary weight to
the CA helmet; (2) The shell protrusions have cavities that is considered
unused real estate; (3) the shell
protrusions do not provide any impact protection (see FIG. 2B); and (4) the
impact will be directly
transferred to the players head potentially at the same acceleration as the
impact, and not properly
distributed over a wide an area as possible to reduce the deformation and
severity of impact (see FIG.
2B).
[000120] As a result, the present invention overcomes many of the
disadvantages observed with
current CA helmets 2101. The present invention relates to various methods,
devices and systems to
retrofit CA helmets to leverage the existing shell protrusions and its
cavities to improve impact
performance of the CA helmet 2101. Impact performance may be improved by
modifying or retrofitting
the shell protrusions 2102 with impact mitigation structures and/or impact
mitigation features to create
crumple zones.
[000121] By leveraging at least one shell protrusion 2102 on the CA helmet
2101, the at least one
shell protrusion 2102 may be deformable, bendable, deflectable, collapsible or
compressible or buckle,
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behaving similarly to "crumple zones." The at least one shell protrusion 2102
may be designed with
impact mitigation structures and/or impact mitigation features to essentially
convert the at least one shell
protrusion to a crumple zone. The crumple zones will be defined as at least
one shell protrusion that is
converted into an impact structural area located in various regions on the CA
helmet that facilitate the
management of incident forces on the helmet during play, thus enhancing
protection from the localized
impact directly to the player's head in a predictable manner. Furthermore,
such crumple zones can
collapse, deform and/or compress in a predictable way to absorb much of the
impact kinetic energy by
reducing the initial impact force and redistribute the impact force before it
reaches the player's head.
[000122] FIGS. 22A-22B depict cross-sectional views of one embodiment of a
traditional CA helmet
2201 with protrusions. The CA helmet 2201 may comprise an outer shell or outer
layer 2202, the outer layer
having an outer surface 2207 and an inner surface 2208, a shell protrusion
2203 that extends outwardly from the
outer surface 2207 of the outer layer 2202. The shell protrusion 2203 may have
a cavity 2204 disposed within,
the cavity 2204 may face towards the head of the wearer 2206. The shell
protrusion 2203 does not contain any
features, cross-sectional shape or other material changes that would provide
or lead to a crumple zone. A force
2209 may impact the CA helmet 2201 causing the rigid protrusion 2203 to
transmit the force directly to the
wearers head 2206, leading to increased concussions and/or other brain
injuries.2
[000123] FIG. 23 depicts a cross-sectional view of one embodiment of CA helmet
2301 that
comprises a shell protrusion 2302 with impact mitigation features 2303 to
create one or more crumple
zones. The CA helmet 2301 may comprise an outer layer 2302, an impact
mitigation layer 2304 and/or at
least one protrusion 2302. The at least one CA helmet shell protrusion 2302
may be modified with impact
mitigation features 2303 that allow the deformation, collapsibility,
compressibility, buckling and/or
impact absorption desired for the particular wearer, the wearer's position,
and/or the wearer's sport or
occupation. The impact mitigation features 2304 may comprise a plurality of
perforations, the plurality of
perforations extending therethrough from the outer surface of the outer shell
protrusion 2302 through to
the inner surface of the outer shell protrusion 2302, thus creating a through-
hole perforation. The
plurality of perforations may be symmetrically aligned or be offset.
[000124] The plurality of perforations may include a variety of different
shapes and/or
configurations to enhance deformation, collapsibility, compressibility,
buckling and/or impact absorption
as shown in FIGS. 24A-24F. Such shapes and/or configurations may include
relief cuts, slits, holes,
openings, polygons 2401, 2042, herringbone shape 2406, zig-zag shapes 2404,
chevron shapes 2405,
auxetic shapes (not shown), reentrant shapes 2403, and/or any combination
thereof. It should be
understood that any shape and configuration can be contemplated as long as the
impact mitigation feature
facilitates or improves impact performance.
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[000125] FIG. 25 depicts a cross-sectional view of an alternate embodiment of
a CA helmet
retrofitted with a crumple zone. The CA helmet 2501 may comprise an outer
layer 2502, an impact
mitigation layer 2505, at least one shell protrusion 2503, and an impact
mitigation structure 2504. The at
least one CA helmet shell protrusion 2503 may incorporate at least one impact
mitigation structure 2504
over the shell protrusions 2503. The at least one impact mitigation structure
2504 can be affixed to the
outer surface of the shell protrusion 2503. Affixation may be a removable
affixation or a permanent
affixation. Affixation may use various methods known in the art, including
press-fit, friction-fit, snaps,
Velcro, magnets, adhesives, molding, sintering, welding, cam locks, screws and
bolts, dovetail,
interlocking protrusions (e.g. LEG0s), over molding and/or any combination
thereof Each of these
coupling mechanisms may utilize existing features of a CA helmet or may
require minor modifications
with penetration through at least one of the CA helmet outer layer, CA helmet
inner layer, the CA impact
absorbing layer, and/or any combination thereof
[000126] FIGS. 26A-26B depicts a cross-sectional view of an alternate
embodiment of CA helmet
retrofitted with a crumple zone. The CA helmet 2601 may comprise an outer
layer 2602, an impact
mitigation layer 2605, at least one shell protrusion 2603, and an impact
mitigation structure 2604. The at
least one CA helmet shell protrusion 2603 may be replaced with at least one
impact mitigation structure
2604. The at least one impact mitigation structure 2604 may match or
substantially match the shape of
the at least one shell protrusion 2603. The at least one CA helmet shell
protrusion 2603 may be removed
with methods known in the art leaving an opening or empty space (FIG. 26A).
The at least one impact
mitigation structure 2604 may mimic the shape and/or configuration of the
existing, removed shell
protrusion 2603 or redesigned to desired custom shape & configuration. The at
least one impact
mitigation structure 2604 may be disposed within the opening and/or over the
opening and affixed to the
CA helmet. The affixation may be a removable affixation or a permanent
affixation. Affixation may use
various methods known in the art, including press-fit, friction-fit, snaps,
Velcro, magnets, adhesives,
molding, sintering, welding, cam locks, screws and bolts, dovetail,
interlocking protrusions (e.g. LEG0s),
over molding and/or any combination thereof Each of these coupling mechanisms
may utilize existing
features of a CA helmet or may require minor modifications with penetration
through at least one of the
CA helmet outer layer, CA helmet inner layer, the CA impact absorbing layer,
and/or any combination
thereof.
[000127] FIG. 27 depicts a cross-sectional view of an alternate embodiment of
CA helmet
retrofitted with a crumple zone. The CA helmet 2701 may comprise an outer
layer 2702, an impact
mitigation layer 2705, at least one shell protrusion 2703, and an impact
mitigation structure 2704. The at
least one CA helmet shell protrusions 2703 may have at least one impact
mitigation structure 2704
disposed within the cavity of the shell protrusion 2703. The at least one
impact mitigation structure 2704
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may mimic the shape and/or configuration of the existing shell protrusion 2603
and may partially fill the
cavity. The at least one CA helmet impact mitigation layer 2705 may be removed
to access the CA
helmet shell protrusion cavity. The at least one impact mitigation structure
may be affixed to the shell
protrusion cavity. Affixation may be a removable affixation or a permanent
affixation. Affixation may
use various methods known in the art, including press-fit, friction-fit,
snaps, Velcro, magnets, adhesives,
molding, sintering, welding, cam locks, screws and bolts, dovetail,
interlocking protrusions (e.g. LEG0s),
over molding and/or any combination thereof Each of these coupling mechanisms
may utilize existing
features of a CA helmet or may require minor modifications with penetration
through at least one of the
CA helmet outer layer, CA helmet inner layer, the CA impact absorbing layer,
and/or any combination
thereof
[000128] FIG. 45 depict a cross-sectional front view of a helmet with crumple
zones. An helmet
4501 comprising an impact mitigation layer; the impact mitigation layer having
a first portion 4504 and a
second portion 4505; and an outer shell, the outer shell having a first region
4502 and a second region
4503, at least a portion of the outer shell first region 4502 being in contact
with the impact mitigation
layer first portion 4502, the outer shell second region 4503 being in contact
with the impact mitigation
layer second portion 4505, at least a portion of the outer shell first region
4502 being offset from a portion
of the outer shell second region 4503, at least a portion of the outer shell
second region 4503 being
independently deflectable relative to at least a portion of the outer shell
first region 4502 as shown in
FIGS. 20A-20I. The outer shell comprises a front shell and a back shell. The
offset comprises at least
one or more openings, and/or one or more tabs. Alternatively, the one or more
tabs may be disposed with
the one or more openings, the one or more tabs span the width of the one or
more openings.
[000129] Impact Mitigation Layer and Impact Mitigation Structures
[000130] In another embodiment, the adjustable helmet system assembly may
further comprise an
impact mitigation layer. The adjustable helmet system includes a helmet, a
locking mechanism, and/or an
impact mitigation layer. The helmet may comprise a front shell (or first
shell) and a back shell (or second
shell), the first or second shell having an external surface and an internal
surface. The locking mechanism,
being movable between a first unlocked position which allows the first and
second shells to slide relative
to each other and a second locked position which inhibits the first and second
shells from sliding relative
to each other. The impact mitigation layer may comprise at least one impact
mitigation structure. The
impact mitigation layer may further comprise a force distribution layer, the
force distribution layer being
a relatively rigid or rigid material. The impact mitigation structure may
comprise a first portion and a
second portion. The first portion and second portion may comprise the same
impact mitigation structure
or different impact mitigation structures. The impact mitigation layer may be
coupled to a first and/or
second shell internal surface. Coupling may occur in different regions within
the first or second shell and
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the coupling may comprise heat staking, gluing, mechanical mounting, Velcro,
and/or any combination
thereof. The impact mitigation structures may comprise at least a portion of
filaments (FIGS. 28A-28D),
at least a portion of laterally supported filaments (LSFs) (FIGS. 29A-29C and
30A-30C), at least a
portion of auxetic structures (FIGS. 31A-31B), at least a portion of liner pod
assemblies (FIGS. 34A-34B
and 35A-35B), TPU (not shown), undulating structures (FIGS. 24D-24F),
inflatable bladders (not shown),
shock bonnets (not shown), at least one foam layer, and/or any combination
thereof
[000131] Furthermore, as disclosed herein, any CA helmet with at least one
shell protrusion may
be leveraged to create or enhance impact protection by converting the at least
one shell protrusion into
crumple zones or impact zones. The at least one shell protrusion may be
converted into a crumple zone or
impact zone by incorporating impact mitigation features or impact mitigation
structures that allow the
collapsibility, compressibility and/or impact absorption. The impact
mitigation structures may comprise
at least a portion of filaments (FIGS. 28A-28D), at least a portion of
laterally supported filaments (LSFs)
(FIGS. 29A-29C and 30A-30C), at least a portion of auxetic structures (FIGS.
31A-31B), at least a
portion of liner pod assemblies (FIGS. 34A-34B and 35A-35B), TPU (not shown),
undulating structures
(FIGS. 24D-24F), inflatable bladders (not shown), shock bonnets (not shown),
at least one foam layer,
and/or any combination thereof.
[000132] In one embodiment, the impact mitigating structures can comprise at
least a portion of
filaments. FIGS. 28A-28D depicts that at least a portion of filaments may be
thin, longitudinally
extending members or be shaped and configured to deform non-linearly in
response to an impact force.
The non-linear deformation behavior is expected to provide improved protection
against high-impact
forces, and/or oblique forces. The non-linear deformation behavior is
described by at least a portion of the
filaments stress-strain profile. The non-linear stress-strain profile
illustrates that there can be an initial
rapid increase in force (region I) followed by a change in slope that may be
flat, decreasing or increasing
slope (region II), followed by a third region with a different slope (region
III).
[000101] In another embodiment, the at least a portion of the filaments may
comprise filaments that
buckle in response to an incident force, where buckling may be characterized
by a localized, sudden
failure of the filament structure subjected to high compressive stress, where
the actual compressive stress
at the point of failure is less than the ultimate compressive stress that the
material is capable of
withstanding. Furthermore, the at least a portion of the filaments may be
configured to deform elastically,
allowing the at least a portion of the filaments to substantially return to
their initial configuration once the
external force is removed. The at least a portion of filaments may extend
between two surfaces, the at
least a portion of filaments having at least one end coupled to the outer
layer and/or the inner layer.
[000133] In another embodiment, the impact mitigating structures can comprise
at least a portion
of a plurality of filaments that are interconnected by laterally positioned
walls or sheets in a polygonal
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configuration, otherwise known as laterally supported filaments (LSF). FIGS.
29A-29C illustrate at least
a portion of the LSF structures 2901, where the filaments 2902 are arranged in
a hexagonal pattern
interconnected by laterally positioned walls 2903. Alternatively, other
polygonal structures and/or
configurations known in the art may be contemplated, such as triangular,
square, pentagonal, hexagonal,
septagonal, octagonal, and/or any combination thereof A plurality of sheets or
lateral walls 2903 can be
secured between adjacent pairs of filaments 2902 with each filament having a
pair of lateral walls
attached thereto. Alternatively, each of the plurality of filaments 2902 may
comprise a lateral wall 2903
extending outwardly therefrom to at least one adjacent filament 2902. In the
disclosed embodiment, the
lateral walls 2903 can be oriented approximately 120 degrees apart about the
filament axis, with each
lateral wall extending substantially along the longitudinal length of the
filament 2902. Accordingly, the
orientation of the lateral walls 2903 may be asymmetric, which at least one
lateral wall 2903 may be
oriented approximately 75 to 135 degrees apart about the filament axis. The
shape, wall thickness or
diameter, height, and configuration of the lateral walls 2903 and/or filaments
2902 may vary as shown in
FIGS. 29A-29C to "tune" or "tailor" the structures to a desired performance.
For example, one
embodiment of a hexagonal structure may have a tapered configuration as shown
in FIG. 29A. The
hexagonal structure can have a top surface 2905 and a bottom surface 2904,
with the bottom surface 2904
perimeter (and/or bottom surface thickness/diameter of the individual
elements) that may be larger than
the corresponding top surface 2905 perimeter (and/or individual element
thickness/diameter). In another
example, the hexagonal structure can have an upper ridge 2906 as shown in FIG.
29C. The upper ridge
2906 can also facilitate connection to another structure, such as an inner
surface of a helmet, an item of
protective clothing, and/or a mechanical connection (e.g., a grommet or plug
having an enlarged tip that is
desirably slightly larger than the opening in the upper ridge of the hexagonal
element).
[000134] Furthermore, the polygonal or hexagonal structures 3001 may be
manufactured as
individual structures or in a patterned array (see FIGS. 30A-30C). The
individual structures 3001 can be
manufactured using an extrusion, investment casting or injection molding
process. Also, they may have
the same shape and configuration with repeating symmetrical arrangement or
asymmetrical arrangement
and/or different shape and configurations with repeating symmetrical
arrangement or asymmetrical
arrangement.
[000135] Conversely, the polygonal or hexagonal structures 3001 may be
manufactured directly
into a patterned array that is affixed to at least one base membrane 3002. The
base membrane may be
manufactured with a polymeric or foam material. The polymeric or foam material
may be flexible and/or
elastic to allows it to be easily bent, twisted or flexed to conform to
complex surfaces. Alternatively, the
polymeric and/or foam material may be substantially rigid. The manufacturing
of each patterned array of
polygonal or hexagonal structures 3001 may include extrusion, investment
casting or injection molding
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process. The base membrane with the polygonal or hexagonal structures may be
affixed directly to at
least a portion of the base or the entirety. Affixing each pattered array of
polygonal or hexagonal
structures 3001 may be arranged in continuous or segmented arrays. Also, the
polygonal or hexagonal
structures 3001 may have the same shape and configuration with repeating
symmetrical arrangement or
asymmetrical arrangement and/or different shape and configurations with
repeating symmetrical
arrangement or asymmetrical arrangement.
[000136] In another embodiment, the impact mitigation structure may comprise
at least a portion of
auxetic structures 3101 as shown in FIGS. 31A-31B. The auxetic structures 3101
may include a plurality
of interconnected members forming an array of reentrant shapes 3102. The
auxetic structures 3101 may
be affixed to a base membrane or directly onto an outer shell. Such auxetic
structures 3101 may be
coupled or affixed to the shell protrusion as a continuous layer or in
segmented arrays 3103. The term
µ`auxetic" generally refers to a material or structure that has a negative
Poisson ratio, when stretched,
auxetic materials or structures become thicker (as opposed to thinner) in a
direction perpendicular to the
applied force. Such auxetic structures can result in high energy absorption
and/or fracture resistance. In
particular, when a force is applied to the auxetic material or structure, the
impact can cause it to expand
(or contract) in one direction, resulting in associated expansion (or
contraction) in a perpendicular
direction. It should be recognized that those skilled in the art could utilize
auxetic structures 3101 to
include differently shaped segments or other structural members and different
shaped voids. For
example, FIG. 31B illustrates an amplified view of one embodiment of an
auxetic structure that is "bone"
or "ribbon" shaped with radiused or arced re-entrant shapes.
[000137] In another embodiment, the impact mitigation layer may further
comprise at least one
foam layer or a portion of a foam layer. The at least one foam layer can
include polymeric foams,
quantum foam, polyethylene foam, polyurethane foam (foam rubber), XPS foam,
polystyrene, phenolic,
memory foam (traditional, open cell, or gel), impact absorbing foam (e.g.,
VN600), ), Ethylene Vinyl
Acetate foam (EVA), Ariaprene foam, latex rubber foam, convoluted foam ("egg
create foam"), Evlon
foam, impact hardening foam, 4.0 Custula comfort foam (open cell low density
foam) and/or any
combination thereof The at least one foam layer may have an open-cell
structure or closed-cell structure.
The at least one foam layer can be further tailored to obtain specific
characteristics, such as anti-static,
breathable, conductive, hydrophilic, high-tensile, high-tear, controlled
elongation, and/or any combination
thereof For example, FIGS. 47A-47B illustrates various views of a portion of a
foam layer. The foam
layer comprises a foam pad 4701. The foam pad 4701 may be positioned on the
crown of the wearer's
head and conform to the curvature of the wearer's head. The portion of a foam
layer may have a length
4704 and a height 4703. The height 4703 may vary at a range between 0.5 inches
to 2 inches. The length
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4704 may vary from 2 inches to 6 inches. The foam pad 4702 may have a
rectangular cross-section. The
foam pad having a recess 4702 disposed on an external surface.
[000138] In another embodiment, the impact mitigation layer may further
comprise at least one
base layer. The at least one base layer may be a rigid and/or substantially
rigid material. The at least one
base layer may have a first surface and a second surface. At least a portion
of an impact mitigation
structure and/or a plurality of impact mitigation structures may be affixed to
at least a portion of the at
least one base layer first and/or second surface. Alternatively, at least one
end of an impact mitigation
structure and/or one end of a plurality of impact mitigation structures may be
affixed to the at least one
base layer first and/or second surface. Desirably, the at least one base layer
may comprise two base
layers, which the impact mitigation structure is disposed in between the two
base layers.
[000139] FIGS. 32A-32C depict cross-sectional views of impact mitigation pads.
In another
embodiment, the impact mitigation layer may further comprise impact mitigation
pads 3201, 3204, 3205.
The one or more impact mitigation pads 3201, 3204, 3205 may comprise a first
material layer 3202, a
second material layer 3203, and an impact mitigation structure 3204. The first
material layer 3202 and/or
the second material layer 3203 may comprise a 2-way stretch material, a 4-way
stretch material, and/or a
foam layer. Additionally, the first material layer 3202 and/or the second
material layer 3203 may further
comprise a polymeric material, such as polypropylene, polyethylene, polyester,
nylon, PVC, PTFE,
and/or any combination thereof It also may be desirable to have a plurality of
individual impact
mitigation pads. Furthermore, the first material 3202 and/or the second
material layer 3203 may be
breathable and wick away moisture easily from the skin while carrying out
various sporting and athletic
activities. For example, the covering may completely or continually cover an
entire array of impact
mitigating structures (not shown). Conversely, the covering may cover at least
a portion of an entire array
of impact mitigating structures. Furthermore, the covering may cover segmented
arrays of impact
mitigating structures or individual impact mitigating structures (not shown).
[000140] In one embodiment, the impact mitigating structures can comprise a
least a portion of
liner pod assemblies as shown in FIGS 33A-33D, 34A-34B, and 35A-35B. FIGS. 33A-
33D depict
various views of one embodiment of an impact mitigation pod assembly 3301. The
one or more liner pod
assemblies 3305 may include at least one individual pod (known as "pods" or
"modular pods") and/or a
connecting mechanism that is coupled to a base membrane layer 3306 and/or
inner shell or inner layer
3303. If the one or more liner pod assemblies 3305 are assembled onto a base
membrane layer 3306, they
will be coupled to the base membrane 3306 in a flat configuration then flexed
or bend to create a shape
that conforms to a wearers head. The base membrane 3306 may be manufactured
with a polymeric or
foam material. The polymeric or foam material may be flexible and/or elastic
to allows it to be easily
bent, twisted or flexed to conform to complex surfaces. Alternatively, the
polymeric and/or foam material
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may be substantially rigid to provide a force distribution layer. The base
membrane 3306 may comprise
tabs 3302 that will be bent around the inner shell 3303 to couple the base
membrane 3306 to the inner
shell 3303. The one or more pod assemblies 3305 can be modular and removably
coupled into any
configuration within the helmet. Each of the one or more pod assemblies 3305
may be positioned
proximate to an adjacent to the one or more pod assemblies 3305, such that the
perimeter of each of the
one or more pod assemblies 3305 may be parallel 3307 to the adjacent one or
more pod assemblies 3305.
[000141] Furthermore, additional spaces 3308 may not be covered in case the
wearer desires
further attachment of additional one or more pod assemblies 3305 and allow
easier flexing capabilities.
Each of the liner pod assemblies 3305 may include easily removable connections
(or removably
connected) to couple to the helmet (e.g., first or second shells), the impact
mitigation layer and/or various
components thereof. Each of the one or more liner pod assemblies may be
manufactured to accommodate
and protect the desired region of the wearer's head. Such plurality of liner
pod assemblies 3305 may
include regions such as one or more of the following: a frontal assembly (or
front), an occipital assembly
(or lower-back), a mid-back assembly (right and/or left sides), a parietal
assembly (or midline), and a
temporal assembly (right and/or left sides), and/or any combination(s) thereof
Alternatively, each of the
one or more liner pod assemblies 3305 may be positioned adjacent to another
liner pod assembly and
connected by a flexible coupling to create a single-piece pod layer. The
single-piece pod layer can be
folded and manipulated to conform to the curvature of the head.
[000142] Alternatively, the one or more pod assemblies 3403 may be coupled
directly to the inner
shell 3402. Each of the one or more liner pod assemblies 3403 may be
manufactured to accommodate
and protect the desired region of the wearer's head. Such plurality of liner
pod assemblies 3403 may
include regions such as one or more of the following: a frontal assembly (or
front), an occipital assembly
(or lower-back), a mid-back assembly (right and/or left sides), a parietal
assembly (or midline), and a
temporal assembly (right and/or left sides), and/or any combination(s)
thereof.
[000143] FIGS. 35A-35B depict two alternative embodiments of a pod assemblies
3501, 3502.
Each of pods assemblies 3501, 3502 comprise a pod body 3503 and a connection
mechanism 3504. The
pod body can comprise a generally triangular shaped body with rounded corners
(an isosceles triangle, for
example), although a variety of other shapes, including other shaped
triangles, squares, pentagons,
hexagons, septagons and/or octagon shapes, could be utilized in a variety of
embodiments. In a similar
manner, alternative shapes having rounded and/or sharp corners and/or edges
may be utilized, as well as
irregular and/or re-entrant shaped bodies, if desired.
[000144] In one exemplary embodiment, one or more liner pod assemblies can be
provided in a
series of sizes and/or thicknesses, such as the pods shown in FIG. 35A-35B,
which depicts pods bodies of
similar sizes but with varying thicknesses, from a first pod body having a
1/4" thickness progressively up
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to a fourth pod body with 1" or 1.25" or greater thickness. Desirably, the
different thickness triangular
pods bodies can be provided with similar external dimensions (i.e., height
and/or width), with only the
thickness differing to any substantial degree, allowing different thickness
pods to be "mixed and
matched" for use with a single helmet liner or other component, and/or other
item of protective clothing.
[000145] The one or more liner assemblies may comprise at least one single
foam layer
construction. The connection mechanism 3504 is removably coupled or
permanently coupled to the single
foam layer pod. The single foam layer pod construction may further comprise
one or more impact
mitigation structures (not shown). The at least one foam layer can include
polymeric foams, quantum
foam, polyethylene foam, polyurethane foam (foam rubber), XPS foam,
polystyrene, phenolic, memory
foam (traditional, open cell, or gel), impact absorbing foam (e.g., VN600), ),
Ethylene Vinyl Acetate
foam (EVA), Ariaprene foam, latex rubber foam, convoluted foam ("egg create
foam"), Evlon foam,
impact hardening foam, 4.0 Custula comfort foam (open cell low density foam)
and/or any combination
thereof. The at least one foam layer may have an open-cell structure or closed-
cell structure. The at least
one foam layer can be further tailored to obtain specific characteristics,
such as anti-static, breathable,
conductive, hydrophilic, high-tensile, high-tear, controlled elongation,
and/or any combination thereof
[000146] Alternatively, the one or more liner pods may comprise a multi-foam
layer construction.
the multilayer layer construction may include a single foam layer, an
enclosure, and impact mitigation
structure, and/or a second foam layer. Such multi-construction layers may
allow the assembly to function
as impact mitigation and comfort, thus, eliminating the need for an additional
comfort liner. In another
embodiment, the one or more liner pod assemblies may comprise a multi-layered
pod construction and a
connection mechanism. The multi-layered pod construction comprises two or more
material layers. The
two or more material layers may include at least one foam layer, a resilient
and/or flexible fabric (e.g., a
two-way or four-way stretch fabric) layer, a plastic layer (e.g.,
polycarbonate), and/or any combination
thereof More specifically, the multi-layered pod construction comprises a top
layer, a first foam layer, a
second foam layer, a bottom layer, and/or any combination thereof Furthermore,
the one or more liner
pod assembly may further comprise an impact mitigation structure (not shown)
or an impact distribution
plate (not shown), and/or an impact mitigation structure and an impact
distribution plate, where the
impact mitigation structure and/or the impact distribution plate are disposed
between the top layer and/or
bottom layer. Each of the two or more layers may be different material layers
and/or the same material
layers. The at least one top layer and at least one bottom layer may be the
same material, or they may be
different materials. The at least one foam layer may be a one single layer,
and/or it may be a plurality of
foam layers (two or more).
[000147] Desirably, the one or more liner pod assemblies may be easily
removable and
interchangeable. For example, in order to increase the amount of protection on
the left and/or right side
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of the helmet, the wearer may simply replace one or more of the liner pods on
the right side of the helmet
with thicker or thinner liner pod assemblies to balance the width reduction,
and ultimately have proper
helmet adjustment to accommodate the exchange of liner pod assemblies.
Alternatively, the player may
choose an "oversized" comfort liner which may be slightly "too big" for the
wearer, and then the wearer
can replace the liner pod assemblies in one or more regions with thinner liner
pod assemblies to "fit" the
helmet more appropriately.
[000148] FIGS. 36A-36C depict various views of one embodiment of a connection
mechanism
3602. The connection mechanism 3601 having a central body 3602, and at least
one longitudinal
extending member 3603. Each of the longitudinal extending members 3603 may be
positioned
symmetrically or asymmetrically around the perimeter of the central body 3602.
Each of the longitudinal
extending members 3603 extends parallel from a surface of the central body
3602. Each of the central
bodies 3602 may comprise at least one fin 3603, that may be positioned around
the perimeter of the
central body 3602 either symmetrically or asymmetrically. The fins 3603 are
sized and configured to fit
within one or more cavities on the base membrane layer and/or the inner shell.
[000149] Inner Shell
[000150] In one embodiment, the adjustable helmet assembly may further
comprise at least one
inner shell, the inner shell being a force distribution layer. The inner shell
being nested within the impact
mitigation layer. The inner shell having an exterior surface and an interior
surface. The at least one inner
shell being a continuous shell that conforms and surrounds the head of the
wearer. Alternatively, the at
least one inner shell may have a two or more portions that align with the
adjustable helmet system.
[000151] Accordingly, the at least one inner shell may be a rigid material.
The at least one inner
shell may be more rigid than the adjustable helmet system and/or more rigid
than the impact mitigation
layer. In some embodiments, the inner shell is five to 100 times stiffer or
more rigid than the adjustable
helmet system and/or the impact mitigation layer. The rigid material may
comprise polycarbonate (PC).
Alternatively, the inner shell comprises a relatively rigid material or
relatively stiff material. The
relatively rigid material may be stiff or rigid enough to withstand breakage
or cracking, but flexible
enough to deform slightly and distribute incident forces after an impact. The
at least one inner shell may
comprise a thermoplastic material. The thermoplastic materials may comprise
polyurethane,
polycarbonate, polypropylene, polyether block amide, and/or any combinations
thereof
[000152] Supplemental Layers
[000153] In another embodiment, the adjustable helmet assembly may further
comprise one or
more supplemental layers. The adjustable helmet system includes a front shell,
a back shell, a locking
mechanism, and/or one or more supplemental layers. The helmet may further
comprise an impact
mitigation layer. The helmet may comprise a front shell (or first shell) and a
back shell (or second shell),
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the first or second shell having an external surface and an internal surface.
The locking mechanism being
movable between a first unlocked position which allows the first and second
shells to slide relative to
each other and a second locked position which inhibits the first and second
shells from sliding relative to
each other. It may be desirous to supplement the impact mitigation layer with
a one or more
supplemental layers, and one or more supplemental layers may be positioned
proximate to the impact
mitigation layer and/or the supplemental layer may be positioned proximate to
the front (or first) or back
(or second) shells. In addition, the supplemental layer may be removably
connected or coupled to the
helmet and/or the impact mitigation layer for additional impact protection,
comfort and fit for a user. The
one or more supplemental layers may comprise one or more of the following: at
least one foam layer, one
or more liner pod assemblies, a one-piece pad assembly, a multi-piece pad
construction, a polycarbonate
layer and/or any combination thereof.
[000154] The supplemental layer may comprise of one or more liner pod
assemblies as disclosed
herein. The liner pod assemblies may be used as either a mitigation structure,
supplemental layer and/or a
combination thereof The one or more liner pod assemblies may be positioned
proximate to the
mitigation structure and/or positioned proximate to the front and or back
shells. Alternatively, the one or
more liner pod assemblies may be coupled to the helmet, the impact mitigation
layer, or both the helmet
and the impact mitigation layer. Furthermore, the one or more liner pod
assemblies may be coupled to a
polycarbonate layer or a rigid polymer layer.
[000155] The one-piece supplemental layer may comprise a plurality of
segmented pads that are
coupled to the adjacent pad through a pivotal or flexible, elastic connection.
Each of the plurality of pads
may comprise a first layer, a second layer, and at least one foam layer. Each
of the plurality of segmented
pads are separated by gap. The foam layer is disposed between the first and
second layer. The gap has a
thickness, the thickness allowing substantial flexibility and/or a pivotal
connection. Each of the plurality
of pads may be placed in specific regions within the helmet, such as at least
one frontal region (or front),
an occipital region (or lower-back), a mid-back region, a parietal region (or
midline), and a temporal
region (right and/or left sides), and/or any combination(s) thereof The first
or second layer may comprise
a two-way stretch fabric, four-way stretch fabric, Neoprene, Ducksan Power
Net, thermoplastic
polyurethane (TPU), any wicking material, any antimicrobial material,
polycarbonate material and/or any
combination thereof
[000156] The at least one foam layer can include polymeric foams, quantum
foam, polyethylene
foam, polyurethane foam (foam rubber), XPS foam, polystyrene, phenolic, memory
foam (traditional,
open cell, or gel), impact absorbing foam (e.g., VN600), Ethylene Vinyl
Acetate foam (EVA), Ariaprene
foam, latex rubber foam, convoluted foam ("egg create foam"), Evlon foam,
impact hardening foam, 4.0
Custula comfort foam (open cell low density foam) and/or any combination
thereof. The at least one
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foam layer may have an open-cell structure or closed-cell structure. The at
least one foam layer can be
further tailored to obtain specific characteristics, such as anti-static,
breathable, conductive, hydrophilic,
high-tensile, high-tear, controlled elongation, and/or any combination
thereof. The at least one foam layer
may comprise of segmented pieces and/or one continuous layer.
[000157] Alternatively, the supplemental layer may comprise a plurality of
individual segmented
pads providing for a multi-piece construction. Each of the plurality of
individual pads may comprise a
first layer, a second layer, and at least one foam layer. The foam layer is
disposed between the first and
second layer. Each of the plurality of individual pads may be placed in
specific regions within the helmet,
such as at least one frontal region (or front), an occipital region (or lower-
back), a mid-back region, a
parietal region (or midline), and a temporal region (right and/or left sides),
and/or any combination(s)
thereof. The first or second layer may comprise a two-way stretch fabric, four-
way stretch fabric,
Neoprene, Ducksan Power Net, thermoplastic polyurethane (TPU), any wicking
material, any
antimicrobial material, polycarbonate material and/or any combination thereof
[000158] In another embodiment, the supplemental layer 4601 may comprise a
plurality of
segmented assemblies 4603 providing for a multi-piece construction as shown in
FIGS. 46A-46B. Each
of the segmented assemblies 4603 comprise one or more liner pod assemblies
4604 as disclosed in FIGS.
35A-35D, and/or one or more individual pads as disclosed in FIG. 32A-32C, each
of the one or more liner
pod assemblies 4604 and/or each the one or more individual pads coupled to a
base layer 4605. The base
layer 4605 may be a polymer, the polymer may be relatively rigid or a rigid
material. Each of the
plurality segmented assemblies 4603 may be placed in specific regions within
the helmet, such as at least
one frontal region (or front), an occipital region (or lower-back), a mid-back
region, a parietal region (or
midline), and a temporal region (right and/or left sides), and/or any
combination(s) thereof
[000159] Example Embodiments
[000160] 1. An adjustable helmet comprising:
[000161] A first shell;
[000162] A second shell, the second shell being slidably attached to the first
shell,
[000163] A locking mechanism, the locking mechanism being movable between a
first unlocked
position which allows the first and second shells to slide relative to each
other and a second locked
position which inhibits the first and second shells from sliding relative to
each other.
[000164] 2. An adjustable helmet comprising:
[000165] A first shell;
[000166] A second shell, the second shell being slidably attached to the first
shell;
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[000167] A locking mechanism, the locking mechanism being movable between an
unlocked
position which allows the first and second shells to slide relative to each
other and a locked position
which prohibits the first and second shells from sliding relative to each
other.
[000168] At least one opening, the at least one opening placed adjacent to, in
proximity to or
within impact zones of the first or second shells, thereby absorbing the
energy from an impact and
reducing the transfer of the impact force to an adjacent portion of the first
or second shell and/or to the
wearer's head.
[000169] 3. The adjustable helmet of claim 2, wherein the impact zones
are located within the
occipital region, temporal region, parietal region, orbit region, the frontal
region, the mandible (front,
right and/or left side) region, the maxilla region, the nasal region,
zygomatic region, the ethmoid region,
the lacrimal region, the sphenoid region and/or any combination thereof
[000170] 4. The adjustable helmet of claim 2, wherein the flexure and/or
local deformation
may occur laterally, perpendicular, oblique, normal to helmet plane, tangent
to helmet plane,
perpendicular to helmet plane, or parallel to helmet plane, and/or any
combination thereof
[000171] 5. The adjustable helmet of claim 2, the at least one opening
may be positioned in
plane tangent to the helmet circumference, in a plane perpendicular or
substantially perpendicular to the
helmet plane, or in an oblique plane to the helmet plane, in a plane parallel
to helmet plane, and/or any
combination thereof
[000172] 6. An adjustable helmet comprising:
[000173] A first shell;
[000174] A second shell, the second shell being slidably attached to the first
shell; and
[000175] A locking mechanism, the locking mechanism including:
[000176] a clamp assembly,
[000177] a plurality of teeth, at least a portion of the plurality of teeth
sized and configured to fit
within a portion of a plurality of recesses, the plurality of teeth disposed
on the first or second shell,
[000178] a plurality of recesses, at least a portion of the plurality of
recesses are sized and
configured to receive the plurality of teeth, the plurality of recesses
disposed on the first or second shell,
the clamp assembly being movable between an unlocked position that allows the
plurality of teeth and the
plurality of recesses to disengage and allows the first and second shells to
slide relative to each other, and
a locked position that allows the a portion of the plurality of teeth and a
portion of the plurality of recesses
to engage and inhibits the first and second shells from sliding relative to
each other.
[000179] 7. An adjustable helmet comprising:
[000180] A first shell;
[000181] A second shell, the second shell being slidably attached to the first
shell; and
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[000182] A locking mechanism, the locking mechanism including:
[000183] a clamp tongue, clamp tongue extending away from the first or second
shell, the clamp
tongue having a plurality recesses, at least a portion of the plurality of
recesses are sized and configured
to receive a portion of a plurality of teeth,
[000184] a plurality of teeth, at least a portion of the plurality of teeth
sized and configured to fit
within a portion of the plurality of recesses, the plurality of teeth disposed
on a portion of the first or
second shell,
[000185] a clamp assembly, the clamp assembly being movable between an
unlocked position that
disengages the portion of the plurality of teeth from the portion of the
plurality of recesses and allows the
first and second shells to slide relative to each other, and a locked position
that allows a portion of the
plurality of teeth and a portion of the plurality of recesses to engage and
inhibits the first and second
shells from sliding relative to each other.
[000186] 8. An adjustable helmet comprising:
[000187] A first shell, the first shell having an external surface and an
internal surface;
[000188] A second shell, the second shell being slidably attached to the first
shell, the second shell
having an external surface and an internal surface; and
[000189] A locking mechanism, the locking mechanism including:
[000190] a clamp tongue, clamp tongue extending away from the first or second
shell, the clamp
tongue having a plurality of recesses, at least a portion of the plurality of
recesses are sized and
configured to receive a portion of a plurality of teeth,
[000191] a plurality of teeth, at least a portion of the plurality of teeth
sized and configured to fit
within a portion of the plurality of recesses, the plurality of teeth disposed
on a portion of the first or
second shell,
[000192] a clamp assembly, the clamp assembly being movable between an
unlocked position that
disengages the portion of the plurality of teeth from the portion of the
plurality of recesses and allows the
first and second shells to slide relative to each other, and a locked position
that allows the a portion of the
plurality of teeth and a portion of the plurality of recesses to engage and
inhibits the first and second
shells from sliding relative to each other.
[000193] a cavity, the cavity being sized and configured to receive the clamp
assembly, the cavity
being disposed within the first or second shells, the clamp assembly having a
top surface and a bottom
surface, the clamp assembly top surface being flush or substantially flush
with the external surface of the
first or second shell.
[000194] 9. An adjustable helmet comprising:
[000195] A first shell, the first shell having an external surface and an
internal surface;
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[000196] A second shell, the second shell being slidably attached to the first
shell, the second shell
an external surface and an internal surface; and
[000197] A locking mechanism, the locking mechanism including; and
[000198] a clamp assembly, the clamp assembly having a clamp body, the clamp
post, and a base
plate;
[000199] a clamp tongue, clamp tongue extending away from the first or second
shell, the clamp
tongue having a top surface, a bottom surface and a first channel, the clamp
tongue top surface having a
plurality of a plurality recesses, at least a portion of the plurality of
recesses are sized and configured to
receive a portion of a plurality of teeth, the channel sized and configured to
receive the clamp post;
[000200] a plurality of teeth, the plurality of teeth disposed on a portion of
the first or second shell
internal surface, at least a portion of the plurality of teeth sized and
configured to fit within a portion of
the plurality of recesses, the first or second shell internal surface further
including a second channel, the
second channel sized and configured to receive the clamp post;
[000201] a cavity, the cavity being sized and configured to receive the clamp
assembly, the cavity
being disposed within the first or second shells external surface, the clamp
assembly having a top surface
and a bottom surface, the clamp assembly top surface being flush or
substantially flush with the external
surface of the first or second shell, the cavity having an aperture, the
aperture sized and configured to
receive the clamp post; the base plate coupled to the clamp post, the base
plate abuts the bottom surface of
the clamp tongue;
[000202] a clamp assembly, the clamp assembly being movable between a locked
position and an
unlocked position, the locked position places tension on the clamp post and
the base plate to compress the
clamp tongue allowing a portion of the plurality of teeth and a portion of the
plurality of recesses on the
clamp tongue to engage and inhibit the first and second shells from sliding
relative to each other, the
unlocked position places compression on the clamp post and the base plate to
release the clamp tongue
allowing the portion of the plurality of teeth and the portion of the
plurality of recesses of the clamp
tongue to disengage, and allow the first and second shells to slide relative
to each other.
[000203] 10. The adjustable helmet of claim 1, 2, 5, 6, 7 or 8, wherein the
adjustable helmet
further comprises an impact mitigation layer.
[000204] 11. The adjustable helmet of claim 1, 2, 5, 6, 7 or 8, wherein the
adjustable helmet
further comprises a supplemental layer.
[000205] 12. The adjustable helmet of claim 1, 2, 5, 6, 7or 8, wherein the
adjustable helmet
further comprises ear protection.
[000206] 13. The adjustable helmet of claim 1, 2, 5, 6, 7 or 8, wherein the
adjustable helmet
further comprises a jaw frame.
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[000207] 14. The adjustable helmet of claim 1, 2, 5, 6, 7 or 8, wherein the
adjustable helmet
further comprises a chin strap.
[000208] 15. The adjustable helmet of claim 10, wherein the supplemental
layer is one or more
liner pod assemblies.
[000209] 16. The adjustable helmet of claim 14, wherein the one or more
liner pod assemblies
are removably connected.
[000210] 17. An improved helmet, comprising:
[000211] a helmet, the helmet having an outer layer and a shell protrusion,
the outer layer having
an outer surface and an inner surface, the shell protrusion extending
outwardly from the outer layer outer
surface, and
[000212] at least one impact mitigation feature, the at least one impact
mitigation feature being
disposed onto the shell protrusion and extending therethrough;
[000213] 18. An improved helmet, comprising:
[000214] a helmet, the helmet having an outer layer and a shell protrusion,
the outer layer having
an outer surface and an inner surface, the shell protrusion extending
outwardly from the outer layer outer
surface, and
[000215] at least one impact mitigation structure, the at least one impact
mitigation structure being
disposed onto the shell protrusion;
[000216] 19. An improved helmet, comprising:
[000217] a helmet, the helmet having an outer layer and a shell protrusion,
the outer layer having
an outer surface and an inner surface, the shell protrusion extending
outwardly from the outer layer outer
surface, the shell protrusion having a cavity disposed within, and
[000218] at least one impact mitigation structure, the at least one impact
mitigation structure being
disposed within the cavity of the shell protrusion;
[000219] 20. An improved helmet, comprising:
[000220] a helmet, the helmet having an outer layer and a shell protrusion,
the outer layer having
an outer surface and an inner surface, the shell protrusion extending
outwardly from the outer layer outer
surface, the shell protrusion having a cavity disposed within, and
[000221] at least one impact mitigation structure, the at least one impact
mitigation structure
replacing the shell protrusion.
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